Molded Case Circuit Breakers & Earth Leakage Circuit Breakers

Technical information

62D4-E-0058
CONTENTS

Chapter 1 Chapter 4
Environment and usage
Protecting low-voltage circuits
precautions
1-1 Description ...................................................................... 4 4-1 Standard conditions ...................................................... 90
1-2 Overcurrent protection .................................................... 5 4-2 Application to special environments ............................. 91
1-3 Phase-loss protection ..................................................... 6 4-3 Connection precautions ................................................ 93
4-4 Malfunction due to transient inrush current .................. 94
Chapter 2
Operating characteristics and
performance Chapter 5 Maintenance inspections
2-1 Overcurrent tripping characteristics ................................ 8 5-1 Faults and causes ......................................................... 96
2-2 Breaking performance .................................................. 11 5-2 Periodic inspections ...................................................... 98
2-3 Overload switching performance .................................. 26 5-3 Replacement recommendations ................................. 100
2-4 Performance with current at 100% ................................ 27
2-5 Durability ....................................................................... 29 Chapter 6 Short-circuit current calculation
2-6 Withstand voltage performance .................................... 31
2-7 Handle operating force and angle ................................. 32
6-1 Calculating short-circuit current .................................. 102
Chapter 3 Selection and application Glossary ....................................................................... 106
3-1 Selection check points .................................................. 34
3-2 Cascade trip applications ............................................. 40
3-3 Selective trip applications ............................................. 43
3-4 Wiring protection ........................................................... 52
3-5 Motor circuit applications .............................................. 57
3-6 Applications on the primary side of transformers ......... 63
3-7 Welder circuit applications ............................................ 66
3-8 Selecting an MCCB for capacitor circuit ....................... 69
3-9 MCCBs for semiconductor circuit ................................. 73
3-10 Protecting SSCs using MCCBs or MMSs .................... 77
3-11 Protecting inverter circuits using MCCBs .................... 79
3-12 MCCBs for high frequency circuits .............................. 80
3-13 MCCBs for DC circuit applications .............................. 81
3-14 MCCBs for UPS applications ....................................... 83
3-15 MCCBs for servo amplifier applications ....................... 84
3-16 Ground fault protection in system applications ............ 85
Introduction
FUJI has employed its comprehensive technical expertise to bring a complete
range of models and features to its line of molded case circuit breakers (MCCBs),
the mainstay for low-voltage overcurrent protection devices.
A more complete line of breakers is combined with better performance and
greater economy to yield a wider selection of products than ever before. Now
with superior applicability, operability and safety, MCCBs have firmly established
their place in the world of overcurrent protection devices for low-voltage circuits.
In response to customer needs, this product line represents some of the safest
and most economical protection systems available. This Technical Information
contains the data that is needed for selecting the most appropriate FUJI MCCB.
It is provided to help you design superior equipment that is safe and cost efficient.
 Protecting low-voltage
Chapter 1 circuits
CONTENTS

1-1 Description ................................................................................................................4

1-2 Overcurrent protection
1-2-1 Overcurrent fault .............................................................................................................5
1-2-2 Overcurrent protection ....................................................................................................5

1-3 Phase-loss protection

1-3-1 Phase-loss fault ...............................................................................................................6
1-3-2 Phase-loss burnout protection (three-phase circuit) .......................................................6

3
 Protecting low-voltage circuits
1 1-1 Description

1-1 Description
The most common faults occurring with low-voltage circuits
are overcurrent (resulting from overload or short-circuit),
ground faults, and phase-loss. A device that will protect
equipment from these faults is therefore needed for reliable
and economical operation. The following section describes
lowvoltage circuit faults along with measures to protect against
them.

4
 Protecting low-voltage circuits
1-2 Overcurrent protection
1

1-2 Overcurrent protection

1-2-1 Overcurrent fault
Overcurrent occurs when a circuit is exposed to current that
is higher than the rated load current. It may be due to short
circuiting in a circuit or to overloading that occurs when a
motor overloads or the rotor locks. In either case, overcurrent
can damage cables, and switching devices and load
equipment connected to a faulty circuit, and can easily spread
to other systems. Overcurrent protection devices are installed
to protect cables and other devices connected to a faulty
circuit while minimizing damage to systems beyond the circuit.

1-2-2 Overcurrent protection

(1) Overload protection
When overcurrent caused by motor overload or a locked
rotor reaches as much as six times the motor rated current, it
results in thermal damage. A circuit breaker is used to ensure
quick tripping to protect the connected devices – the breaker
having a lower operating characteristic curve than the heating
characteristic curves of the motor winding and cable.

(2) Short-circuit protection

Since short-circuit current is caused by a short in a circuit,
it tends to be fairly large. The actual amount is calculated
from the power supply capacity, power supply voltage, and
cable impedance to the shorting point. It can vary significantly
with low-voltage circuits from near the rated load current to
several hundred times the rated load current depending on the
shorting point. This has prompted studies first to find circuit
breakers with rated capacities that can handle massive short-
circuit current, and second to look into materials that can
protect against the electromagnetic forces generated by the
shortcircuit current peak value Isp and the joule integral (I2t) in
circuits before the breaker cuts current off completely.

5
 Protecting low-voltage circuits
1 1-3 Phase-loss protection

1-3 Phase-loss protection

1-3-1 Phase-loss fault
(1) Three-phase power supply circuit
A phase-loss fault occurs when there is a disconnection in one
of the phase wires. If a motor continues running under those
conditions, the result is an imbalance in the current flow to the
motor windings that can generate enough heat to burn out the
windings. This can develop eventually into a short-circuit or
ground fault.
A phase-loss protection device protects the motor windings
from burning and prevents the fault from developing into a
wider problem.

1-3-2 Phase-loss burnout protection

(threephase circuit)
One way to prevent phase-loss from burning the motor or
severely lowering its durability is to disconnect it from the
circuit. For economic reasons, it is recommend that this be
done using a manual motor starter (MMS) with phase-loss
protection capability.

6
 Operating characteristics
Chapter 2 and performance
CONTENTS

2-1 Overcurrent tripping characteristics

2-1-1 Types of tripping ............................................................................................................8
2-1-2 Factors affecting overcurrent trip characteristics ...........................................................8

2-2 Breaking performance

2-2-1 Short-circuit current breaking ......................................................................................11
2-2-2 Breaking characteristics ..............................................................................................12
2-2-3 Arc space ....................................................................................................................13
2-2-4 Reset time ...................................................................................................................25

2-3 Overload switching performance .................................................................26

2-4 Performance with current at 100%
2-4-1 Temperature rise .........................................................................................................27
2-4-2 Internal resistance and power consumption ................................................................27

2-5 Durability
2-5-1 Switching durability ......................................................................................................29
2-5-2 Trip switching durability ...............................................................................................29
2-5-3 Rated ultimate short-circuit breaking performance .....................................................29
2-5-4 Switching durability of accessories ..............................................................................30

2-6 Withstand voltage performance

2-6-1 Rated power frequency withstand voltage (IEC 60947-1, 2) .......................................31
2-6-2 Rated impulse withstand voltage (IEC 60947-1, 2) .....................................................31

2-7 Handle operating force and angle ................................................................32

7
 Operating characteristics and performance
2 2-1 Overcurrent tripping characteristics

2-1 Overcurrent tripping characteristics

2-1-1 Types of tripping (3) Short-time delay trip
Overcurrent tripping in MCCBs occurs in three different ways This type of tripping has a short-time delay to handle the
depending on the amount of overcurrent. For line protection selective trip coordination of low-voltage circuits.
use in general, the breakers use an inverse-time delay trip and
instantaneous trip (dual trip-element characteristic).
Some breakers use a short-time delay in addition to the 2-1-2 Factors affecting overcurrent trip
inverse-time delay trip and the instantaneous trip mainly for characteristics
selective trip coordination. This is particularly true with larger
breakers (ternary trip-element characteristic). There are basically three types of overcurrent tripping:
Fig. 2-1 shows a dual trip-element characteristic curve while thermalmagnetic, hydraulic-magnetic and solid-state. The
Fig. 2-2 shows a ternary trip-element characteristic curve. effect of each varies with the principle involved.
Table 2-1 shows models organized by the type of trip device.
(1) Inverse-time delay trip (long-time delay)
Table 2-1 Breaker trip devices
This type of tripping delays the tripping time of the breaker at
a rate inversely proportional to the amount of overcurrent. It is Trip device MCCB type ELCB type (Reference)
available as either a thermal-magnetic type that uses ordinary Thermal- The following models not The following models not
bimetal elements or as a hydraulic-magnetic type that uses oil magnetic included. included.
dashpot damping. The trip is also referred to as a long-time
delay trip to distinguish it from the shorter tripping time of the Hydraulic- BW32AAG, BW32SAG EW32AAG, EW32EAG
magnetic EW32SAG
short-time delay trip.
BW50AAG, BW50EAG EW50AAG, EW50EAG
BW50SAG, BW50RAG EW50SAG, EW50RAG
(2) Instantaneous trip BW63EAG, BW63SAG EW63EAG, EW63SAG
BW63RAG EW63RAG
This trips the circuit breaker immediately when there is BW100AAG EW100AAG
relatively significant overcurrent like short-circuit current. BW100EAG EW100EAG

Fig. 2-1 Dual trip-element characteristic Solid state BX100, BX160

BX250, BX400
BX630, BX800
BX1000
Inverse time-delay trip (Long-time delay trip) BX1250
BX1600
BW1000RAE
BW1250RAE
BW1600RAE
Operating time

Instantaneous trip (1) Ambient temperature

If an MCCB is used at a temperature other than the
reference ambient temperature at which its overcurrent
trip characteristics are prescribed, the long-time delay trip
characteristic changes. Therefore, the choice of MCCB must
consider the cataloged temperature correction curve and
Current overcurrent trip characteristics. As Table 2-2 shows, the effects
of ambient temperature on the overcurrent trip characteristics
Fig. 2-2 Ternary trip-element characteristic of an MCCB vary according to the type of trip device.

Table 2-2 Ambient temperature effects on overcurrent trip

Inverse time-delay trip (Long-time delay trip) Trip device Effect of ambient temperature change
Thermalmagnetic The minimum current for trip operation will
decrease when the ambient temperature exceeds
the reference ambient temperature, and vice
versa. This means that a lower overcurrent makes
Operating time

Short-time delay trip the bimetal reach the operating temperature

as the ambient temperature rises, because the
bimetal’s operating temperature is constant.
Instantaneous trip Hydraulicmag- Although the minimum value of trip current
netic remains unchanged, the operating time varies
depending on the ambient temperature, as the
viscosity of silicon fluid in the oil dashpot varies.
Current

8
 Operating characteristics and performance
2-1 Overcurrent tripping characteristics
2

(2) Hot-start and cold-start (3) Mounting angle

The cataloged characteristic curve that is called the cold-start MCCBs are designed to be mounted in parallel with the
characteristic represents the operating characteristic of an vertical plate. Note that different mounting other than
MCCB that has just been energized at the reference ambient the standard position could alter the MCCB’s operating
temperature. The MCCB’s operating characteristic appearing characteristic (see Table 2-4). The effect of mounting angle on
when overcurrent has just begun to flow after a long period of the overcurrent trip characteristic varies depending on the type
steady load current is called the hot-start characteristic. of trip device as shown in Table 2-3.
In general, 50% or 75% of the rated load current is used
as the steady state load current, and the associated Table 2-3 Effect of mounting angle on overcurrent trip
operating characteristics are called the 50% or 75% hot-
start characteristics. With both thermal-magnetic and Trip device Effect of mounting angle
hydraulicmagnetic type MCCBs, the hot-start operating time is Thermalmagnetic Although the heat radiation is slightly dependent
shorter than the cold-start operating time as shown in Fig. 2-3. on mounting angle, the operating characteristic
is hardly affected by it. Therefore, the effect of
Fig. 2-3 Hot and cold start characteristics mounting angle is negligible.
Hydraulicmag- The gravity on the iron core in the cylinder varies
netic depending on the mounting angle. The mounting
angle, then, affects the operating characteristics.
Cold start
In general, a backward or forward tilt not
exceeding the angle of 10° from the vertical plate
has negligible effect. A larger angle than this
needs the current rating correction as indicated in
the Table 2-4.
Operating time

Hot start

Current

(4) Mounting angle effects

Special care must be taken regarding the mounting angle operating current varies with the mounting angle because
of MCCBs because the angle will affect their operating gravity affects the plunger in the oil dashpot.
characteristics. In a hydraulic-magnetic type, for example, the
Table 2-4 Current rating correction for hydraulic-magnetic MCCB by mounting angle

Mounting angle Vertical * Horizontal Horizontal Slant 15° Slant 45° Slant 15° Slant 45°
(upside (backward) (backward) (forward) (forward)
down)
ON ON ON
P ON
ON
ON OFF
MCCB ELCB (Reference) OFF ON OFF OFF OFF OFF

BW32AAG, BW32SAG EW32AAG, EW32EAG 100% 85% 115% 95% 90% 105% 110%
EW32SAG
correction factor

BW50AAG, BW50EAG EW50AAG, EW50EAG

Rated current

BW50SAG, BW50RAG EW50SAG, EW50RAG

BW63EAG, BW63SAG EW63EAG, EW63SAG
BW63RAG EW63RAG
BW100AAG EW100AAG
BW100EAG EW100EAG
Note: * A 100% rated current correction factor is maintained on a vertical line at any angle as shown in the figure below.
View from P

ON

OFF
ON OFF OFF ON

OFF

ON

9
 Operating characteristics and performance
2 2-1 Overcurrent tripping characteristics

(5) Frequencies
(a) Commercial frequencies (50Hz, 60Hz)
The characteristics of breakers are generally the same at 50
and 60Hz.

(b) Direct current (DC)

If an MCCB designed for operation in an AC circuit were used
in a DC circuit, its operating characteristics would change as
shown in Table 2-5. Hence, an MCCB exclusively designed for
operation in a DC circuit has to be used on this occasion.

Table 2-5 Operating characteristic changes for DC circuit application

Trip device Inverse time-delay trip characteristic Instantaneous trip characteristics Operating characteristic curve
Thermal-magnetic None The instantaneous trip current is
higher than that for an AC circuit.

Operating time
The rate of variation depends DC
on the ampere-frame size, rated AC
current and model. The trip current
can be as high as 140% of the AC Current
value.

Hydraulic-magnetic The minimum operating current at DC

is about 110–140% of that for AC.

Operating time
DC
AC

Current

Solid state Not applicable

(c) High frequency

For operation at higher frequencies, such as 400 or 750Hz,
the current rating of a thermal-magnetic MCCB has to be
derated due to the heat generated by the skin effect in the
conductors or the eddy current in the iron core. The rate of
reduction slightly depends on the ampere-frame size and the
rated current. The available current rating at 400Hz decreases
to 70–80% of the rated current.
As the iron loss lowers the attractive force of the trip device,
the instantaneous trip current will increase. Hydraulic-magnetic
MCCBs cannot be used in a high-frequency circuit because
the operating characteristics will change greatly due to the
temperature rise of the moving iron core and the reduced
attractive force by the high frequency.

10
 Operating characteristics and performance
2-2 Breaking performance
2

2-2 Breaking performance

2-2-1 Short-circuit current breaking
Fig. 2-4 illustrates how a short-circuit current is broken. Fig. 2-5 Three-phase short-circuit current breaking test
oscillograms 460V AC, 3-phase
Fig. 2-4 Short-circuit current breaking
Supply voltage
Available short-circuit current
2 2 460 V
Actual short-circuit current
to be broken
Beginning of
L1 phase voltage
short-circuit fault
Current L1 phase current
69.7 kA
Time to open contact
Arcing time L2 phase voltage
Total opening time
Restrike voltage 65.6 kA
Recovery voltage L2 phase current
Arc voltage
Voltage L3 phase voltage
L3 phase current
78.2 kA

When a short-circuit fault occurs and a short-circuit current Non current-limiting type
flows, the instantaneous trip device is actuated to quickly open
the contacts. An arc is generated between the contacts the
moment the moving contact separates from the stationary
Supply voltage
contact.
The rapid movement of the moving contact away from the 2 2 460 V
stationary contact draws the arc rapidly across the arc horn
and into the arc quencher. The arc lengthens as the distance L1 phase voltage
between the contacts increases, until the electromotive force 14.9 kA
L1 phase current
generated between the grid and arc current drives the arc 39.5 kA
deeply into the V-notches in the magnetic sheets composing L2 phase voltage
the arc quencher’s grid. The grid thus splits the arc into a L2 phase current
series of shorter arcs. With the arc stretched and split up in
this way, the resistance and the arc voltage increase due to L3 phase voltage
the combined action of cooling by the grid, the rising pressure L3 phase current
in the arc quencher, and the cathode effect. The arc is
43.0 kA
extinguished (quenched) when the arc voltage becomes larger
than the supply voltage. At this time, a voltage equivalent
to the supply voltage (recovery voltage) appears across the Current-limiting type
contacts. This condition is called completion of breaking.
In general, a circuit in which a large short-circuit current
occurs has a low power factor. If the arc is quenched
at the zerocrossing point of the short-circuit current, a
circuit-constant, dependent oscillating transient voltage is
superimposed on the recovery voltage that appears across
the contacts. This voltage is called the restrike voltage and
can cause rearcing between the contacts if the isolation
between the contacts has not recovered sufficiently. To achieve
complete breaking without rearcing, powerful arc-quenching
action and sufficient contact spacing must be ensured quickly.
To achieve current-limiting breaking, current-limiting MCCBs
use the electromotive force generated across two parallel
conductors to quickly open the contacts without waiting for
instantaneous trip, while increasing the arc voltage in an
extremely short time. In DC circuits, the current does not fall
to zero as in AC circuits. The arc voltage must be increased
through a powerful arc quenching effect to suppress the
current: arc quenching is complete when the supply of energy
needed to maintain arcing is no longer available.
Fig. 2-5 shows the three-phase short-circuit current breaking
test oscillograms.

11
 Operating characteristics and performance
2 2-2 Breaking performance

2-2-2 Breaking characteristics (3) Operating duty

(1) Breaking performance Under conditions where the displayed rated breaking capacity
is specified, breakers will break properly at an operating duty
The characteristics that define MCCB breaking performance
of “O” -t- “CO” for Icu and “O” -t- “CO” -t- “CO” for Ics (where
are the rated short-circuit breaking capacity, peak let-through
t is three minutes or the time it takes to reset the breaker,
current, and maximum let-through I2t. The rated short-circuit
whichever is longer). All this is done at the rated voltage and
breaking capacity is defined by the rated ultimate short-circuit
frequency. After the breaker trips, however, the rated current
breaking capacity (Icu), and the rated service short-circuit
may or may not flow, but the breaking capacity, durability,
breaking capacity (Ics).
letthrough current and overload switching capacity will be
diminished. Therefore, replace the breaker with a spare as
(2) Rated short-circuit breaking capacity quickly as possible. If current must be supplied with the same
Fig. 2-6 is a typical oscillogram of a short-circuit current. In the breaker, conduct a maintenance inspection that looks closely
figure, t=0 denotes the time the short-circuit fault occurred. at the operating conditions prior to the breaker tripping, the
The rated load current was flowing at the supply voltage before amount of short-circuit current, as well as future operating
the short-circuit fault occurred. The current by several factors conditions. Special attention must be paid to temperature rise
of ten flows after the occurrence of the short circuit. Because as well.
the load current immediately after the short-circuit fault
contains a DC component, the current flow is asymmetrical
with respect to the zero-current line, with the DC component
being attenuated rapidly. The curve C-C’ represents the DC
component of the asymmetrical short-circuit current, and is
indicates the current that would flow if a short circuit occurred.
This current is called the available short-circuit current.
− Rt
iS=iAC+iDC=Im [sin (Zt+ø−M)−e L sin (ø−M)]
ø: Making phase angle
cosM: Short-circuit power factor
The value of the above equation reaches
its maximum when (ø−M) = ± π .
2
Im = Em
√ R2+(ZL)2

Fig. 2-6 Short-circuit current oscillogram

i P
A

C
X

iS A'
Y

i B C'
t
0

1/2 cycle B'

P'
iS: Short-circuit current
C-C': Intermediate line between the envelopes A-A' and B-B'
P-P': 1/2 cycle after occurrence of short-circuit fault
X: AC component of short-circuit current
Y: DC component of short-circuit current

The rated breaking current of an MCCB is represented as

X/ √2 , the effective value of the AC component 1/2 cycle after
the occurrence of the short-circuit fault. For a three-phase
circuit, the rated breaking current is represented the average
of
the three phases.
For DC circuits, the maximum available short-circuit current is
used.

12
 Operating characteristics and performance
2-2 Breaking performance
2

(4) Breaking characteristics flow until completion of breaking. The time interval between
the occurrence of a short-circuit fault and the opening of the
When the magnitude of an overcurrent exceeds a certain
contacts is called the contact opening time. The time interval
limit, the instantaneous trip device is actuated to open the
between completion of breaking and quenching of the arc
pole immediately. The minimum current that can actuate the
generated by contact opening is called the arcing time. The
instantaneous trip device is called the instantaneous trip
sum of the contact opening time and the arcing time, or the
current, which is expressed as a symmetrical effective value.
period of time from the occurrence of a short-circuit fault to
With thermal-magnetic MCCBs, the instantaneous trip current
completion of breaking, is called the total opening time. Table
setting is adjustable because their instantaneous trip device
2-7 lists the contact opening times, arcing times, and total
is installed separately from the inverse time-delay trip device.
opening times of MCCBs at breaking of the rated breaking
This eases coordination with other devices. Fig. 2-7 shows
current.
the progress of time after the start of short-circuit current

Fig. 2-7 Current breaking process

Current
Available short-circuit current
Short-circuit occurrence

Maximum peak available

short-circuit current
let-through current
Maximum peak
Breaking
current
Arc voltage

Time
Contact Zero-crossing point of
opening
Load current time Arcing time short-circuit current
Short-circuit current
Total opening time breaking point
Recovery voltage
Restrike voltage

(5) Maximum let-through current and maximum value, the smaller the thermal effects on the cable and load
breaking I2t equipment. Fig. 2-8 to 2-9 and Fig. 2-10 to 2-11 give the
maximum let-through I2t or maximum let-through current, and
The current that would flow through a short circuit without a
available short-circuit current of MCCBs.
circuit breaker is called the available short-circuit current. It is
the short-circuit current that is determined from the impedance
map at circuit breaker selection, not the current that is actually
interrupted by the circuit breaker. The current that actually
2-2-3 Arc space
flows through the circuit is smaller than the available short- When a short-circuit current is broken, an ionized gas is
circuit current. As the trip device in the circuit breaker is emitted from the breaker’s line side exhaust vent and, because
actuated to open the contact immediately on occurrence of a this gas is conductive, it could induce an interphase short
short circuit, the arc voltage is increased to inhibit current flow. circuit or ground fault if it bridges adjacent bare live parts or
This is equivalent in effect to having a variable resistor, called a bare live part and an adjacent grounded metallic surface.
an arc resistor, connected in series in the circuit. Because this is potentially hazardous, an arc space (insulation
Current-limiting circuit breakers that take advantage of the space) is required for safety.
magnetic repulsion force represent an application of this Table 2-7 lists the arc spaces required for specific conditions.
principle; current-limiting breaking is done before the short- When wiring is done, live parts should be either taped or
circuit current reaches its peak value. protected by insulating barriers in the ranges specified in
The maximum current that can flow through the circuit breaker Table 2-7 to allow for conditions that could be encountered
is called the maximum let-through current, which is expressed while the MCCB is in service. Improved insulation may be
as a peak value. The smaller the maximum let-through current, needed outside the arc space depending on the service
the less mechanical stress is imposed on the cable and load conditions of the MCCB.
equipment. With a high short-circuit current having a low
power factor, the transient peak value is more than twice the
symmetrical effective value. In mechanical stress studies,
therefore, a choice must be made between the current-
limiting type and the non-current-limiting type, along with full
allowance for electromotive force.

The squared product of the let-through current, or tt21i2dt from

t1 short-circuit occurrence time t1 to completion of breaking
time t2, is called the maximum breaking I2t. The smaller this

13
 Operating characteristics and performance
2 2-2 Breaking performance

Fig. 2-8 Max. let-through I2t 230V AC

100
80

50

30

20
(16)* 35mm2

(12) 30mm2
10
(8.18) 25mm2 8 BW630EAG, RAG, HAG BW800EAG, RAG, HAG
R H
(6.8) 22mm2 EW630EAG, RAG, HAG EW800EAG, RAG, HAG
BW630RAGU, HAGU BW800RAGU, HAGU
E
EW630RAGU
5
BW400EAG, SAG, RAG, HAG
(3.35) 16mm2 S R H
Max. let-through current

EW400EAG, SAG, RAG, HAG

(2.7) 14mm2 3 E BW400EAGU, SAGU, RAGU, HAGU
EW400SAGU, RAGU, HAGU
2 E H
ò i2dt (x106A2s)

BW250EAG, EAGU R BW250JAG, RAG, HAG BW250JAGU, RAGU

EW250JAG, RAG, HAG EW250JAGU, RAGU
(1.31) 10mm2 J

(1.05) 8mm2 1
R H BW50HAG (40, 50A) BW125JAG, RAG, HAG (40 to 125A)
0.8 EW50HAG (40, 50A) EW125JAG, RAG, HAG (40 to 125A)
J BW125JAGU, RAGU (40 to 125A)
EW125JAGU, RAGU (40 to 125A)
(0.471) 6mm2 0.5 BW32SAG BW50, 63SAG
(0.4) 5.5mm2 BW50, 63EAG EW50, 63SAG
BW100AAG BW50, 63RAG BW50RAGU
0.3 EW32SAG BW100EAG BW100EAGU
EW50, 63EAG EW50, 63RAG EW50RAGU
(0.21) 4mm2 EW100AAG EW100, EAG, EAD EW100EAGU
0.2

(0.13) 3.5mm2 BW32, 50AAG BW50HAG (30A) BW125JAG, RAG, HAG (30A)
EW32, 50AAG EW50HAG (30A) EW125JAG, RAG, HAG (30A)
0.1 BW125JAGU, RAGU (30A)
(0.082) 2.5mm2 0.08 R H EW125JAGU, RAGU (30A)
J
R H BW50HAG (20A) BW125JAG, RAG, HAG (20A)
(0.05) 2mm2 0.05 J EW50HAG (20A) EW125JAG, RAG, HAG (20A)
R H BW125JAGU, RAGU (20A)
J EW125JAGU, RAGU (20A)
0.03
BW50, 63EBG BW50HAG (15A) BW125JAG, RAG, HAG (15A)
EW50, 63EBG EW50HAG (15A) EW125JAG, RAG, HAG (15A)
0.02 BW125JAGU, RAGU (15A)
EW125JAGU, RAGU (15A)
BW32, 50, 63SBG BW50RBGU
EW32, 50, 63SBG EW50RBGU
0.01
1 2 5 10 20 50 100 200 500 1000
Available short-circuit current (rms. sym.) (kA)
Note: * The parentheses ( ) indicate approximate tolerances I2t for each wire gauge. (See Table 3-11, Chapter 3.)

14
 Operating characteristics and performance
2-2 Breaking performance
2

Fig. 2-9 Max. let-through I2t 400V AC

100
80

50

30
BW630EAG, RAG, HAG BW800EAG, RAG, HAG
EW630EAG, RAG, HAG EW800EAG, RAG, HAG
20
(16)* 35mm2 BW630RAGU, HAGU BW800RAGU, HAGU
EW630RAGU
H
(12) 30mm2
R BW400EAG, SAG, RAG, HAG
10 E H EW400EAG, SAG, RAG, HAG
(8.18) 25mm2 R BW400EAGU, SAGU, RAGU, HAGU
8
(6.8) 22mm2 S EW400SAGU, RAGU, HAGU
E

5 H BW250JAG, RAG, HAG BW250JAGU, RAGU

R
EW250JAG, RAG, HAG EW250JAGU, RAGU
(3.35) 16mm2 BW250EAG J
EW250EAG
(2.7) 14mm2 3 E BW50HAG (40, 50A) BW125JAG, RAG, HAG (40 to 125A)
H EW50HAG (40, 50A) EW125JAG, RAG, HAG (40 to 125A)
R
BW125JAGU, RAGU (40 to 125A)
2 EW125JAGU, RAGU (40 to 125A)
J

(1.31) 10mm2
Max. let-through current

(1.05) 8mm2 1
0.8 BW50, 63SAG
ò i2dt (x106A2s)

EW50, 63SAG BW50, 63RAG BW50RAGU

BW100EAG BW100EAGU
EW50, 63RAG EW50RAGU
(0.471) 6mm2 0.5
BW32SAG
(0.4) 5.5mm2 BW50, 63EAG BW50HAG (30A) BW125JAG, RAG, HAG (30A)
EW32SAG EW50HAG (30A) EW125JAG, RAG, HAG (30A)
0.3 EW50, 63EAG BW125JAGU, RAGU (30A)
EW125JAGU, RAGU (30A)
(0.21) 4mm2 R H
0.2 J BW50HAG (20A) BW125JAG, RAG, HAG (20A)
BW32, 50AAG R H EW50HAG (20A) EW125JAG, RAG, HAG (20A)
EW32, 50AAG J BW125JAGU, RAGU (20A)
(0.13) 3.5mm2 BW100AAG J R H EW125JAGU, RAGU (20A)
0.1 BW50HAG (15A) BW125JAG, RAG, HAG (15A)
(0.082) 2.5mm2 0.08 EW50HAG (15A) EW125JAG, RAG, HAG (15A)
BW125JAGU, RAGU (15A)
EW125JAGU, RAGU (15A)
BW32, 50, 63SBG
(0.05) 2mm2 0.05
BW32, 50, 63SBG

0.03

0.02
BW50, 63EBG
EW50, 63EBG

0.01
1 2 5 10 20 50 100 200 500 1000

Available short-circuit current (rms. sym.) (kA)

Note: * The parentheses ( ) indicate approximate tolerances I2t for each wire gauge. (See Table 3-11, Chapter 3.)

15
 Operating characteristics and performance
2 2-2 Breaking performance

Fig. 2-10 Peak let-through current 230V AC

1000
800
600
500
400
300 Unlimited

200
Peak let-through current (kA)

BW630EAG, RAG, HAG

100 BW800EAG, RAG, HAG
90 EW630EAG, RAG, HAG
80 EW800EAG, RAG, HAG
70 H
R
60 BW400EAG, SAG, RAG, HAG
50 E H EW400EAG, SAG, RAG, HAG
S R
40 BW250JAG, SAG, RAG, HAG
E H BW160JAG, SAG, RAG
S R EW250JAG, SAG, RAG
30 E H
BW250EAG J S R EW160JAG, SAG, RAG
EW250EAG J
20 BW50HAG (40, 50A)
BW125JAG, SAG, RAG, HAG (40 to 125A)
EW125JAG, SAG, RAG (40 to 125A)

10 BW50HAG (30A)
H
S R BW125JAG, SAG, RAG, HAG (30A)
J H
S R EW125JAG, SAG, RAG (30A)
J
S R H
BW50HAG (20A)
5 J
BW125JAG, SAG, RAG, HAG (20A)
EW125JAG, SAG, RAG (20A)
BW50, 63RAG BW50HAG (15A)
BW100EAG BW125JAG, SAG, RAG, HAG (15A)
BW32SAG BW50, 63SAG EW50, 63RAG EW125JAG, SAG, RAG (15A)
2 BW50, 63EAG EW50, 63SAG EW100EAG
BW100AAG
EW32SAG
BW32, 50AAG EW50, 63EAG
EW32, 50AAG EW100AAG
1
1 2 5 10 20 50 100 200 500 1000

16
 Operating characteristics and performance
2-2 Breaking performance
2

Fig. 2-11 Peak let-through current 400V AC

1000
800
600
500
400
300 Unlimited

200
BW630EAG, RAG, HAG
Peak let-through current (kA)

BW800EAG, RAG, HAG

EW630EAG, RAG, HAG
100 EW800EAG, RAG, HAG
90 BW400EAG, SAG, RAG, HAG
80
70 H EW400EAG, SAG, RAG, HAG
60 R
H BW250JAG, SAG, RAG, HAG
50 E R BW160JAG, SAG, RAG
40 S H EW250JAG, SAG, RAG
E
R EW160JAG, SAG, RAG
30 S H
BW250EAG J R BW50HAG (40, 50A)
EW250EAG E S BW125JAG, SAG, RAG, HAG (40 to 125A)
20 J EW125JAG, SAG, RAG (40 to 125A)

H BW50HAG (30A)
R BW125JAG, SAG, RAG, HAG (30A)
S
J R H
S EW125JAG, SAG, RAG (30A)
10 J
R H
J S
BW50HAG (20A)
BW125JAG, SAG, RAG, HAG (20A)
EW125JAG, SAG, RAG (20A)
5 BW50HAG (15A)
BW125JAG, SAG, RAG, HAG (15A)
BW50, 63RAG EW125JAG, SAG, RAG (15A)
BW100EAG
BW32SAG BW50, 63SAG EW50, 63RAG
BW50, 63EAG EW50, 63SAG EW100EAG
2 BW100AAG
EW32SAG
BW32, 50AAG EW50, 63EAG
EW32, 50AAG EW100AAG

17
 Operating characteristics and performance
2 2-2 Breaking performance

Current and energy limiting curves Maximum permissible cable stresses

The table below indicates the maximum permissible thermal
Ics = 100 % Icu stresses for cables depending on their insulation, conductor (Cu
The exceptional limiting capacity of the BX range greatly or Al) and their cross-sectional area (CSA). CSA values are
reduces the forces created by fault currents in devices. given in mm² and thermal stresses in A2s.
The result is a major increase in breaking performance. CSA 1.5 mm² 2.5 mm² 4 mm² 6 mm² 10 mm²
In particular, the service breaking capacity Ics is equal to 100 PVC Cu 2.97x104 8.26x104 2.12x105 4.76x105 1.32x106
% of Icu. Al 5.41x105
The Ics value, defined by IEC standard 60947-2, is guaranteed PRC Cu 4.10x104 1.39x105 2.92x105 6.56x105 1.82x106
by tests comprising the following steps: Al 7.52x105
break three times consecutively a fault current equal to 100 CSA 16 mm² 25 mm² 35 mm² 50 mm²
% of Icu
PVC Cu 3.4x106 8.26x106 1.62x107 3.31x107
check that the device continues to function normally, that is:
Al 1.39x106 3.38x106 6.64x106 1.35x107
it conducts the rated current without abnormal temperature
PRC Cu 4.69x106 1.39x107 2.23x107 4.56x107
rise
Al 1.93x106 4.70x106 9.23x106 1.88x107
protection functions perform within the limits specified by the
standard
suitability for isolation is not impaired. Example
Is a Cu/PVC cable with a CSA of 10 mm² adequately
Longer service life of electrical installations protected by an BX160F?
Current-limiting circuit breakers greatly reduce the negative The table above indicates that the permissible stress is
effects of short-circuits on installations. 1.32x106 A2s.
All short-circuit currents at the point where an BX160F (Icu =
Thermal effects 35 kA) is installed are limited with a thermal stress less than
Less temperature rise in conductors, therefore longer service life for 6x105 A2s (curve page 19).
cables.
Cable protection is therefore ensured up to the limit of the
Mechanical effects breaking capacity of the circuit breaker.
Reduced electrodynamic forces, therefore less risk of electrical
contacts or busbars being deformed or broken.
Electromagnetic effects
Fewer disturbances for measuring devices located near electrical
circuits.
Economy by means of cascading
Cascading is a technique directly derived from current
limiting. Circuit breakers with breaking capacities less than the The limiting capacity of a circuit breaker is its aptitude to let through a
prospective short-circuit current may be installed downstream current, during a short-circuit, that is less than the prospective short-
of a limiting circuit breaker. The breaking capacity is reinforced circuit current.
by the limiting capacity of the upstream device. It follows that
substantial savings can be made on downstream equipment (Isc)
and enclosures. Prospective
Isc peak
Prospective
Current and energy limiting curves current
The limiting capacity of a circuit breaker is expressed by two
curves which are a function of the prospective short-circuit Prospective
current (the current which would flow if no protection devices Isc
were installed): Limited Isc
the actual peak current (limited current) peak
Actual
thermal stress (A2s), i.e. the energy dissipated by the short- current
circuit in a conductor with a resistance of 1 :. Limited
Isc
Example (t)
What is the real value of a 150 kA rms prospective short-circuit (i.e.
330 kA peak) limited by an BX250L upstream ? The exceptional limiting capacity of the BX range is due to the rotating
The answer is 30 kA peak (curve page 19). double-break technique (very rapid natural repulsion of contacts and
the appearance of two arc voltages in-series with a very steep wave
front).

18
 Operating characteristics and performance
2-2 Breaking performance
2

Current and energy limiting curves

Energy-limiting curves
Voltage 400/440 V AC Voltage 660/690 V AC
Limited energy Limited energy
9 9
10 10

5 5
3 3
2 2
1.41 1.41
8 8
10 10

5 5
3 3
2 2
7 7
10 10
2 2
As 5 As 5 BX630
R H BX630 H
3 BX400 3 BX400
2 2 R
6 6 BX250
10 R H BX250
10
R, H
BX100 BX100
5 BX160
5 BX160
3 3
2 2
5 5
10 10

5 5
3 3
2 2
2 3 4 6 10 20 30 40 50 70 100 150 200 300 2 3 4 6 10 20 30 40 50 70 100 150 200 300
kA rms kA rms

19
 Operating characteristics and performance
2 2-2 Breaking performance

Current and energy limiting curves

Current-limiting curves
Voltage 400/440 V AC Voltage 660/690 V AC
Limited short-circuit current (k peak) Limited short-circuit current (k peak)
300 300

200 200
146 146

100 100
80 80
70 70
60 BX630
60
50 H 50
BX400
40 R 40 BX630
k kÂ
30 BX250 30 H BX400
H BX100
R
BX160
20 20 R BX250
BX100
BX160
10 10 R, H
8 8
7 7
6 6
5 5
4 4
2 3 4 6 10 20 30 40 50 70 100 200 300 2 3 4 6 10 20 30 40 60 100 200 300
65
kA rms kA rms

20
 Operating characteristics and performance
2-2 Breaking performance
2

Current-limiting curves
Thermal-stress curves
Voltage 400/440 V AC (1) Voltage 660/690 V AC
Limited energy Limited energy

BX800H
BX800R BX1000H BX800H
BX1000R BX1250H BX1000H
BX1250R BX1600H BX1250H
BX1600R BX1600H

BX800R
BX1000R
BX1250R
BX1600R

R H BX630 H BX630
BX400 BX400
R

R H BX250
BX250 R
BX100
BX100 BX160
BX160

Rated short-circuit current (kA rms) Rated short-circuit current (kA rms)

Current-limiting curves
Voltage 400/440 V AC (1) Voltage 660/690 V AC
Limited short-circuit current (k peak) Limited short-circuit current (k peak)

BX800H
BX1000H
BX1250H BX800H
BX1600H BX1000H
BX800R BX1250H
BX1000R BX1600H
BX1250R BX800R
BX1600R BX1000R
BX1250R
BX1600R
H BX630
R kÂ
k BX400
H BX630
H
R BX250 BX400
BX100 R BX250
BX160
BX100
BX160

Rated short-circuit current (kA rms) Rated short-circuit current (kA rms)

(1) Valid for 480 V Nema.

21
 Operating characteristics and performance
2 2-2 Breaking performance

Table 2-7 Arc space, mm

Fig 1 Fig 2 Fig 3 Fig 7 Fig 8 Fig 9 Fig 12

C

D3
A

D1

A
A
F

D3

B
C
B

D2
Fig 4 Fig 5 Fig 6

Direct connection Crimp terminal connection Fig 10 Fig 11

of electric wire

Basic type Bare earth plate Upper and lower Distance of side Distance of front plate Dimensions of taping or Wire
distance plate insulation barrier exposure
A B C Coated plate Bare plate In the case of taping In the case
F F Crimp Busbar of insulation
terminal connection barrier
MCCB ELCB 440V AC 230V AC 440V AC 230V AC 440V AC 230V AC 440V AC 230V AC 440V AC 230V AC D1 D2 D3
BW32SBG EW32SBG 10 10 20 20 10 10 0 0 − − − 20 −
BW50EBG EW50EBG 10 10 20 20 10 10 0 0 − − − 20 −
BW50SBG EW50SBG 10 10 20 20 10 10 0 0 − − − 20 −
BW63EBG EW63EBG 10 10 20 20 10 10 0 0 − − − 20 −
BW63SBG EW63SBG 10 10 20 20 10 10 0 0 − − − 20 −
BW32AAG EW32AAG − 10 − 10 − 10 − 0 − 0 10 10 5
− EW32EAG 10 10 30 30 20 15 0 0 0 0 30 30 5
BW32SAG EW32SAG 10 10 30 30 20 15 0 0 0 0 30 30 5
BW50AAG EW50AAG − 10 − − − 10 − 0 − 0 10 10 10
BW50EAG EW50EAG 10 10 30 30 25 15 0 0 0 0 30 30 10
BW50SAG EW50SAG 30 10 40 40 25 15 0 0 0 0 30 30 10
BW50RAG EW50RAG 50 25 50 50 25 15 0 0 10 5 Length of exposed section in live section + 20
50 50 10
BW50HAG EW50HAG 60 60 80 80 50 20 5 0 10 5 80 80 −
BW63EAG EW63EAG 10 10 30 30 25 15 0 0 0 0 30 30 −
BW63SAG EW63SAG 30 10 40 40 25 15 0 0 0 0 30 30 −
BW63RAG EW63RAG 50 25 50 50 25 15 0 0 10 5 50 50 −
BW100AAG EW100AAG − 10 − 20 − 15 − 0 − 0 50 50 −
BW100EAG EW100EAG 50 25 50 50 25 15 0 0 0 5 50 50 −
BW125JAG EW125JAG 40 40 50 50 25 20 0 0 10 5 50 50 −
BW125RAG EW125RAG 40 40 60 60 25 20 5 0 10 5 50 50 −
BW125HAG EW125HAG 60 60 80 80 50 20 5 0 10 5 80 80 −
BW250EAG EW250EAG 40 40 50 50 50 15 0 0 10 5 80 80 −
BW250JAG EW250JAG 40 40 60 60 50 20 0 0 10 5 80 80 −
BW250RAG EW250RAG 40 40 80 80 50 20 5 0 10 10 80 80 −
BW250HAG EW250HAG 60 60 80 80 60 60 5 0 10 10 80 80 −
BW400EAG EW400EAG 100 80 100 80 50 20 0 0 10 5 100 100 −
BW400SAG EW400SAG 100 80 100 80 50 20 0 0 10 5 100 100 −
BW400RAG EW400RAG 100 80 100 80 80 40 5 0 20 10 100 100 −
BW400HAG EW400HAG 100 80 100 80 80 40 5 0 20 10 100 100 −
BW630EAG EW630EAG 100 80 100 80 80 40 0 0 10 5 100 100 −
BW630RAG EW630RAG 100 80 100 80 80 40 5 0 20 10 100 100 −
BW630HAG EW630HAG 100 100 120 100 80 40 5 0 20 10 120 120 −
BW800EAG EW800EAG 100 80 100 80 80 40 0 0 10 5 100 100 −
BW800RAG EW800RAG 100 80 100 80 80 40 5 0 20 10 100 100 −
BW800HAG EW800HAG 120 100 120 100 80 40 5 0 20 20 120 120 −
BW1000RAE − 120 120 150 150 80 80 0 0 0 0 −
Larger than the dimensions of
BW1250RAE − 120 120 150 150 80 80 0 0 0 0 −
exposed section in live section
BW1600RAE − 150 150 150 150 100 100 0 0 0 0 −
Fig 1, 2, 3, 9 Fig 4, 5, 6, 9 Fig 8, 10 Fig 12 Fig 7 Fig 11 Fig 7, 8 Fig 1

22
 Operating characteristics and performance
2-2 Breaking performance
2

Installation example
Safety clearance
Minimum distance between two Minimum distance between circuit
adjacent circuit breakers breaker and front or rear panels
Front F
panel

A1

B=0 F
Bare or painted sheetmetal Note: if F < 8 mm: an insulating screen or long
terminal shield is mandatory.

Minimum distance between circuit breaker and top, bottom or side panels

D1 D1 D1
D1

D2 C1

Devices without accessories. Devices with interphase barriers or long or short terminal shields.

Minimum safety clearances for BX100 to 630

Operating voltage Clearance (mm)
Between Between device and sheetmetal
devices Painted sheet metal Bare sheet metal
A1 C1 D1 D2 C1 D1 D2
U d 440 V
for devices equipped with:
no accessories 0 0 30 30 5 40 40
short terminal shields 0 0 30 30 5 40 40
interphase barriers 0 0 0 0 5 0 0
long terminal shields 0 0 0 0 0 0 0
440 V < U d 600 V
for devices equipped with:
short terminal shields 0 0 30 30 10 40 40
interphase barriers (1) 0 0 0 0 20 10 10
long terminal shields (2) 0 0 0 0 10 10 10
U > 600 V
for devices equipped with:
short terminal shields 0 10 50 50 20 100 100
Spacing ” 60 mm Spacing > 60 mm
long terminal shields 0 10 30 30 20 40 40
(1) Only for BX100 to 250. Bars
(2) For all cases.
F1 F1

Clearances with respect to live bare busbars

Minimum clearances for BX100 to 630
Operating voltage Clearances with respect to live bare busbars
spacing y 60 mm spacing > 60 mm
F1 F2 F1 F2
U < 440 V 350 350 80 80
F2 F2
440 V d U d 600 V 350 350 120 120
U > 600 V prohibited: insulating screen required between device and busbars Bars
These clearances can be reduced for special installations as long as the configuration is checked by
tests. Live busbars.

23
 Operating characteristics and performance
2 2-2 Breaking performance

Safety clearances and minimum distances

General rules BX800 to 1600 (fixed devices)
When installing a circuit breaker, minimum distances (safety
clearances) must be maintained between the device and
panels, bars and other protection devices installed nearby. A (*)
B A (*) B
These distances, which depend on the ultimate breaking
capacity, are defined by tests carried out in accordance with
standard IEC 60947-2.
If installation conformity is not checked by type tests, it is also
necessary to:
use insulated bars for circuit-breaker connections
block off the busbars using insulating screens.

146.5
F (*) An overhead clearance of 50 mm
is required to remove the arc chutes.

Insulated parts Metal parts Live parts

A 0 120 180
B 0 10 60
F Datum

Installation example
Painted sheetmetal

Direct connection by bare Connection by cables with lugs, Connection by insulated bars, Rear connection or plug-in
cables, devices with terminal devices with terminal shields. devices with terminal shields. base, devices with terminal
shields. shields.

Minimum dimensions (mm) A

BX800 to 1600 250

24
 Operating characteristics and performance
2-2 Breaking performance
2

2-2-4 Reset time

The reset time is the time it takes the trip device in a breaker type breakers, on the other hand, can be reset immediately
to return to its normal operating condition after breaking after tripping. It takes the plunger a few minutes to return to its
automatically. With thermal-magnetic types, the directly heated normal position, however, which means that trip characteristics
type used in small-frame products takes a minute or so to will not be as specified for a short amount of time. The
reset while the indirectly heated type takes slightly longer. The operating time is virtually the same with massive current, such
two types function virtually identically with significant current, as with instantaneous tripping, because the plunger hardly
such as with short-circuit current breaking. Hydraulic-magnetic moves in those situations. Table 2-8 shows breaker reset
times.
Table 2-8 Reset time (230V)
Type Overcurrent trip device Reset time (Minute)
MCCB ELCB (Reference) With overload current With short-circuit current
tripping (Icu) breaking
(200% of current)
BW32AAG, SAG EW32AAG, EAG, SAG Hydoraulic-magnetic Immediately Immediately
BW50AAG, EAG, SAG, RAG EW50AAG, EAG, SAG, RAG
BW63EAG, SAG, RAG EW63EAG, SAG, RAG
BW100AAG, EAG EW100AAG, EAG
BW50HAG EW50HAG Thermal-magnetic 1 2
BW125JAG, RAG, HAG EW125JAG, RAG, HAG
BW250EAG, JAG, RAG, HAG EW250EAG, JAG, RAG, HAG
BW400EAG, SAG, RAG, HAG EW400EAG, SAG, RAG, HAG Thermal-magnetic 2 2
BW630EAG, RAG, HAG EW630EAG, RAG, HAG
BW800EAG, RAG, HAG EW800EAG, RAG, HAG
BX100 − Electronic Immediately Immediately
BX160
BX250
BX400
BX630
BX800
BX1000 BW1000RAE
BX1250 BW1250RAE
BX1600 BW1600RAE

25
 Operating characteristics and performance
2 2-3 Overload switching performance

2-3 Overload switching performance

Contacts should have no overt signs of damage, burn out, welding and other electrical or mechanical faults after an overload
switching test is conducted in accordance with the stipulations (IEC 60947) in Table 2-9.

Table 2-9 Overload switching test conditions

Rated current Circuit condition Operating system and No. of operations

(A)
Voltage Current Power factor/ Frequency Manual closing Manual closing Operations
time constant Manual opening Automatic opening per hour
100 or less Max. operating AC: 6 times the Power factor: 45 to 62Hz 9 3 120
voltage (Ue) rated current 0.5 Total: 12
More than 100, 120
(In), 150A min.
but 315 or less
More than 315, DC: 2.5 times Time constant: 120
but 630 or less the rated current 2.5ms
(In)

.OTES s 4HIS TEST MAY BE CONDUCTED ON BREAKERS RATED ABOVE !

s 4HE TRIP DEVICE MUST BE SET AT MAXIMUM IF THIS TEST IS CONDUCTED ON BREAKERS WITH ADJUSTABLE TRIP DEVICES
s )F THE MAXIMUM CURRENT SET FOR THE SHORT CIRCUIT TRIP DEVICE IN A BREAKER IS LOWER THAN THE TEST CURRENT THEN THE CIRCUIT MUST BE BROKEN AUTOMATICALLY ALL  TIMES
required in the test.
s )N EACH MANUAL OPERATING CYCLE THE BREAKER MUST CLOSE THE CIRCUIT LONG ENOUGH TO ALLOW CURRENT TO REACH MAXIMUM LEVELS 4HIS MUST NOT TAKE LONGER THAN 
seconds however.

26
 Operating characteristics and performance
2-4 Performance with current at 100%
2

2-4 Performance with current at 100%

2-4-1 Temperature rise
At the rated current, the temperature of MCCBs and ELCBs (reference) should not rise above the values given in Table 2-10 at
any specification.

Table 2-10 MCCB and ELCB temperature rise at the rated current

Terminal Handle Cover top

IEC 60947-2 Table 7 80K 35K 50K
JISC 8201-2-1, JISC 8201-2-2 80K 35K 50K
UL 489 Table 40.1 (reference) 50K 60K 60K
UL 60947-4-1 Table 2.3 (reference) 65K 35K 50K

2-4-2 Internal resistance and power consumption

The breakers used in AC circuits have the following losses.
1. Resistance loss in conductive parts and contacts
2. Iron loss induced in internal magnetic materials
The losses are so small at commercial frequencies that they
can be ignored as is often done with resistance losses.
Table 2-11 shows average internal resistance per phase as
well as power consumption at the rated current for MCCBs.

27
 Operating characteristics and performance
2 2-4 Performance with current at 100%

Table 2-11 MCCB internal resistance and power consumption

Type Rated current Internal Power Type Rated current Internal Power
(A) resistance consumption (A) resistance consumption
(m:/phase) (W/3-phase) (m:/phase) (W/3-phase)
BW32AAG 3 101.0 2.7 BW125JAG 15 14.0 9.5
BW32SAG 5 39.3 2.9 BW125RAG 20 11.8 14.2
BW32AFC 10 11.4 3.4 BW125HAG 30 5.0 13.5
15 5.8 3.9 40 2.7 13.0
20 3.8 4.6 50 2.1 15.8
30 2.3 6.2 60 1.5 16.2
32 2.1 6.4 75 1.1 18.6
BW32SBG 3 116.0 3.1 100 0.8 24.0
5 50.5 3.8 125 0.7 32.8
10 13.8 4.1 BW250EAG 125 0.56 26.3
15 6.5 4.4 BW250JAG 150 0.49 33.1
20 4.1 5.2 BW250RAG 160 0.39 30.0
30 2.8 7.6 BW250HAG 175 0.39 35.8
32 2.8 8.6 200 0.31 37.2
BW50AAG 5 39.3 2.9 225 0.24 36.5
BW50EAG 10 11.4 3.4 250 0.21 39.4
BW50SAG 15 5.8 3.9 BW400EAG 250 0.25 47.0
BW50AFC 20 3.8 4.6 BW400SAG 300 0.21 57.0
30 2.3 6.2 BW400RAG 350 0.19 70.0
32 2.1 6.4 BW400HAG 400 0.18 86.4
40 1.7 8.2 BW630EAG 500 0.117 88.0
50 1.4 11.0 BW630RAG 600 0.097 105.0
BW50RAG 10 10.9 3.3 BW630HAG 630 0.097 116.0
15 5.3 3.6 BW800EAG 700 0.087 128.0
20 3.3 4.0 BW800RAG 800 0.070 134.0
30 1.8 4.9 BW800HAG
32 1.7 5.2 BW1000RAE 400 0.062 29.8
40 1.2 5.8 500 0.062 46.5
50 1.0 7.5 600 0.062 67.0
BW50HAG 15 14.0 9.5 700 0.062 91.1
20 11.8 14.2 800 0.062 119.0
30 5.0 13.5 900 0.062 150.7
40 2.7 13.0 1000 0.062 186.0
50 2.1 15.8 BW1250RAE 500 0.04 30.0
BW50EBG 3 116.0 3.1 600 0.04 43.2
BW50SBG 5 50.5 3.8 700 0.04 58.8
10 13.8 4.1 800 0.04 76.8
15 6.5 4.4 1000 0.04 120.0
20 4.1 5.2 1200 0.04 172.8
30 2.8 7.6 1250 0.04 187.5
32 2.8 8.6 BW1600RAE 700 0.022 32.3
40 1.7 8.2 800 0.022 42.2
50 1.5 11.3 900 0.022 53.5
BW63EAG 60 0.9 9.7 1000 0.022 66.0
BW63SAG 63 0.9 10.7 1200 0.022 95.0
BW63RAG 1400 0.022 129.4
BW63EBG 60 1.1 11.9 1500 0.022 148.5
BW63SBG 63 1.1 13.1 1600 0.022 169.0
BW100AAG 60 0.9 9.7
BW100AFC 63 0.9 10.7 Type Rated Fixed device Additional power / pole (W)
75 0.7 11.8 current R/pole P/pole Plug-in Ammeter Transfo.
100 0.6 18.0 (A) (m:) (W) module module
BW100EAG 50 1.0 7.5 BX100 40 0.84 1.34 0.2 0.1 0.1
60 0.9 9.7 100 0.468 4.68 1 0.2 0.2
63 0.9 10.7 BX160 160 0.36 9.16 2.6 0.5 0.5
75 0.7 11.8 BX250 100 0.27 2.73 1.6 0.2 0.2
100 0.6 18.0 250 0.28 17.56 6.3 1.3 1.3
BX400 400 0.12 19.2 9.6 2.4 2.4
BX630 630 (1) 0.1 39.69 19.49 5.95 5.95
BX800 800 0.026 15 –
BX1000 1000 0.026 22 –
BX1250 1250 0.026 44 –
BX1600 1600 0.026 74 –
(1) The power loss values for the withdrawable circuit breakers are given for 570 A.

28
 Operating characteristics and performance
2-5 Durability
2

2-5 Durability 2-5-2 Trip switching durability

2-5-1 Switching durability There are two types MCCB trip action: trip actuated by the
overcurrent trip device, and trip actuated by accessories such
MCCBs do not require the high-frequency switching as a shunt trip or undervoltage trip device. Trip switching
capability needed by magnetic motor starters because their durability is defined as 10% of the total number of switching
primary purpose is to protect cables or equipment against operations both with and without current as given in Table
overcurrents. Further, longer durability would detract from the 2-12. This value, however, assumes mechanical switching,
economy of the MCCBs because they are furnished with a or the breaking of the rated current by a shunt trip device. If
switch mechanism and a trip mechanism. IEC specifies the the trip is caused by an overcurrent, the durability is lowered
switching performance and durability requirements listed in depending on the magnitude of the overcurrent because of
Table 2-12. the resultant contact wear and arc quencher thermal damage.
According to IEC 60947-2, trip switching durability is defined
as the current and the number of switching operations for an
overload test as given in Table 2-12.

Table 2-12 MCCB switching durability

Circuit conditions Rated current Operations No. of operations

(A) per hour*
Voltage Current Power factor/ Frequency With current Without Total
time constant current
Rated Rated current Power factor: 45 to 62 100 or less 120 1500 8500 10000
operating (In) 0.8
More than 100, 120 1000 7000 8000
voltage (Ue) Time constant:
but 315 or less
2ms
More than 315, 60 1000 4000 5000
but 630 or less
More than 630, 20 500 2500 3000
but 2500 or less
More than 2500 10 500 1500 2000
Notes: * An operating cycle constitutes one making and breaking. It should be s &OR BREAKERS EQUIPPED WITH A SHUNT TRIP DEVICE OR AN UNDERVOLTAGE
closed for 1.5 to 2 seconds. trip device, 5% of the total number of switching operations should be
s 4HE BREAKER MUST CLOSE THE CIRCUIT LONG ENOUGH TO ALLOW CURRENT TO REACH allocated at the beginning and the end of the test for operation with
maximum levels. This must not take longer than 2 seconds however. those tripping devices.

2-5-3 Rated ultimate short-circuit breaking Table 2-13 Rated ultimate short-circuit breaking

performance Circuit conditions Number of breaks

See Table 2-13. Single-pole Maximum rated O-t-CO at each pole: 1 time
The operating duty for breaking current corresponding to breaking* operating voltage O: Breaker opens when a
the rated ultimate short-circuit breaking capacity (Icu) of the 25% of (Icu) rated short-circuit occurs in a
MCCB can be broken twice with O-t-CO. However, CO after ultimate short-circuit closed circuit.
interval t was implemented in case you need to restart when breaking capacity CO: Breaker closes and
opens in a shorted
it is not clear what caused the breaker to trip before you have
circuit.
eliminated the cause of the fault. This does not mean that the t: Time interval between
breaker can function for long after it has tripped, however, and O and CO
you should replace it with a new one after short-circuit current Three minutes or the
breaking has occurred. time it takes to reset
the MCCB, whichever
is longer.
Single or Maximum rated O-t-CO: 1 time
three-phase operating voltage
breaking Rated ultimate
short- circuit breaking
capacity (Icu)

Notes: * Applies to multi-circuit breakers in voltage phase grounding-type

distribution systems.

29
 Operating characteristics and performance
2 2-5 Durability

2-5-4 Switching durability of accessories

As Table 2-14 indicates, MCCB accessories whose switching
capability requires consideration can be grouped into two
types: accessories that are actuated by the switching of the
MCCB, and those that are actuated when the MCCB trips.
Accessories of the former type require a switching durability
equivalent to the associated MCCB. They provide the durability
specified by the total number of switching operations both with
and without current as given in Table 2-14.

Table 2-14 Switching durability of MCCB accessories

Accessory actuated by Accessory actuated when

switching of MCCB the MCCB trips
Accessory Auxiliary switch (W) Alarm switch (K)
built into the Shunt trip device (F)
MCCB Undervoltage trip device (R)
External Operating handle (N, V)
accessory Motor operating
mechanism (M)
Durability Total number of switching 10% or more of the total
operations both with and number of switching
without current as given operations both with and
in Table 2-12. without current as given in
Table 2-12.

30
 Operating characteristics and performance
2-6 Withstand voltage performance
2

2-6 Withstand voltage performance Fig. 2-12 Test circuit for rated impulse withstand voltage
characteristics
2-6-1 Rated power frequency withstand voltage
Impulse generator
(IEC 60947-1, 2) Rs L
(1) Circuit breaker body
The breaker should function normally with 2000V applied for
Air gap Specimen
one minute at the following locations if it is rated at 300V or
less, and with 2500V applied for one minute at the following
Capacitor
locations if it is rated at more than 300V and 600V or less. Ro To the CRT
s "ETWEEN TERMINALS ON THE POWER SUPPLY SIDE AND THE LOAD
side with the breaker in the open or tripped state.
s "ETWEEN OPPOSITE POLARITY TERMINALS WITH THE BREAKER CLOSED
(However, electronic components used for ground-fault
detection and overvoltage protection elements must be
electrically left open.)
s "ETWEEN THE LIVE PART AND GROUND WITH THE BREAKER OPEN AND Fig. 2-13 Impulse voltage waveform
closed. 100

(2) Breakers with non-electrically operated 90

accessories Voltage (%)
(a) Between accessory circuits and the breaker live part
The breaker should withstand the following voltages above the 50
rated voltage applied to the control circuit for one minute.
60V or less: 1000V 30
More than 60V, but less than 600V:
(Rated voltage) u 2 + 1000V (1500V min.)

(b) Between accessory circuits and ground 1.2μs

The breaker should withstand (the rated voltage of the 50μs
accessory u 2 + 1000V) applied for one minute. The 1000V
are between contacts on the auxiliary switch.
Fig. 2-14 Evaluating MCCBs by waveform observation
(3) Electrically operated breakers
Good
(a) Between electrically operated circuits and the live part
of the breaker
The breaker should withstand (the rated voltage of the breaker Not good
u 2 + 1,000V) applied for one minute.

(b) Between electrically operated circuits and ground

The breaker should withstand (the rated voltage of the
electrically operated device u 2 + 1000V) applied for one
minute. The 1000V are on the operating motor.

2-6-2 Rated impulse withstand voltage

(IEC 60947-1, 2)
Use the test circuit shown in Fig. 2-12 in order to check rated
impulse withstand voltage performance. Apply the 1.2 u 50μs
voltage waveform shown in Fig. 2-13 between the live part
of the specimen and metal plate. Observe the waveform by
memory scope to determine whether the MCCB passes or not.
(See Fig. 2-14.)

Conduct the test on a new specimen. Use one that came with
the accessory, such as an auxiliary switch (W), alarm switch
(K), shunt trip device (F) or undervoltage trip device (R).
Fig. 2-14 shows the criteria for the test.

31
 Operating characteristics and performance
2 2-7 Handle operating force and angle

2-7 Handle operating force and angle

Table 2-15 shows the operating force and angle of handles by type of breaker.

Table 2-15 Handle operating force and angle

Line side
ON

D
Trip

C
OFF
Reset
r A
B

MCCB ELCB (Reference) Operating force (N·m) Operating angle ( ) Dimensions (mm) Rotating
radius r
OFF ON Trip ON OFF Trip Reset A B C D (mm)
ON OFF Reset
BW32AAG-2P EW32AAG-2P 0.42 0.54 0.89 22 15 4 17.5 57 84 9.5 – 26.9
BW32SAG-2P
BW50AAG-2P EW50AAG-2P
BW50EAG-2P
BW50SAG-2P
BW50RAG-2P
BW63EAG-2P
BW63SAG-2P
BW63RAG-2P
BW100EAG-2P
BW32AAG-3P EW32AAG-3P 0.59 0.7 1.6 22 15 4 17.5 57 84 9.5 – 26.9
EW32EAG-3P
BW32SAG-3P EW32SAG-3P
BW50AAG-3P EW50AAG-3P
BW50EAG-3P EW50EAG-3P
BW50SAG-3P EW50SAG-3P
BW50RAG-3P EW50RAG-3P
BW63EAG-3P EW63EAG-3P
BW63SAG-3P EW63SAG-3P
BW63RAG-3P EW63RAG-3P
BW100AAG-3P EW100AAG-3P
EW100EAG-2P
BW100EAG-3P EW100EAG-3P
BW125JAG-2P 1.18 1.3 1.67 21 10 11 12.5 33.7 95 – 0.8 61.3
BW50HAG-3P 1.72 1.9 2.45 21 10 11 12.5 33.7 95 – 0.8 61.3
BW125JAG-3P EW125JAG-3P
BW125SAG-2P,3P EW125SAG-3P
BW125RAG-2P,3P EW125RAG-3P
BW125HAG-3P
BW125JAG-4P EW125JAG-4P 2.35 2.6 3.35 21 10 11 12.5 33.7 95 – 0.8 61.3
BW125SAG-4P EW125SAG-4P
BW125RAG-4P EW125RAG-4P
BW160EAG-3P EW160EAG-3P 3.37 3.8 4.9 21 10 11 12.5 33.7 95 – 0.8 61.3
BW160JAG-2P,3P EW160JAG-3P
BW160RAG-2P,3P EW160RAG-3P
BW250EAG-3P EW250EAG-3P
BW250JAG-2P,3P EW250JAG-3P
BW250RAG-2P,3P EW250RAG-3P
BW250HAG-3P
BW160JAG-4P EW160JAG-4P 4.6 5.21 6.74 21 10 11 12.5 33.7 95 – 0.8 61.3
BW160SAG-4P EW160SAG-4P
BW160RAG-4P EW160RAG-4P
BW250JAG-4P EW250JAG-4P
BW250SAG-4P EW250SAG-4P
BW250RAG-4P EW250RAG-4P
BW400EAG-2P,3P EW400EAG-3P 8 7.5 14 22 10.5 6.7 13.5 54.6 146 4.3 – 91.4
BW400SAG-2P,3P EW400SAG-3P
BW400RAG-2P,3P EW400RAG-3P
BW400HAG-2P,3P EW400HAG-3P
BW400RAG-4P EW400RAG-4P 10.93 10.25 19.13 22 10.5 6.7 13.5 54.6 146 4.3 – 91.4
BW400HAG-4P EW400HAG-4P
BW630EAG-3P EW630EAG-3P 11 10 20 22 10.5 6.7 13.5 54.6 146 4.3 – 91.4
BW630RAG-3P EW630RAG-3P
BW630HAG-3P EW630HAG-3P
BW800EAG-3P EW800EAG-3P
BW800RAG-3P EW800RAG-3P
BW800HAG-3P EW800HAG-3P
BW630RAG-4P 15.03 13.67 27.33 22 10.5 6.7 13.5 54.6 146 4.3 – 91.4
BW630HAG-4P
BW800RAG-4P
BW800HAG-4P

32
 Selection and application
Chapter 3 CONTENTS
3-1 Selection check points
3-1-1 MCCB selection check points ...................................................................................... 34
3-1-2 Selecting and MCCB ratings ........................................................................................ 36
3-1-3 Overcurrent protection principle ................................................................................... 37
3-1-4 Protective coordination ................................................................................................ 37

3-2 Cascade trip applications

3-2-1 Conditions for cascade (backup) trip coordination ......................................................40
3-2-2 Criteria for cascade (backup) trip coordination ...........................................................40

3-3 Selective trip applications

3-3-1 Selective trip coordination of breakers ........................................................................43
3-3-2 Selective trip coordination between MCCBs and high-voltage side protective devices ......48
3-3-3 Selective trip coordination with a high-voltage fuse .....................................................49

3-4 Wiring protection

3-4-1 Description ..................................................................................................................52
3-4-2 Thermal characteristics of wire ...................................................................................52
3-4-3 Application of protective devices .................................................................................54

3-5 Motor circuit applications

3-5-1 Description ..................................................................................................................57

3-6 Applications on the primary side of transformers

3-6-1 Inrush current for transformer excitation .....................................................................63
3-6-2 Selecting an MCCB for transformer primary circuit ......................................................63
3-6-3 Transformer primary-side circuit selection ...................................................................64

3-7 Welder circuit applications

3-7-1 Arc welders .................................................................................................................66
3-7-2 Resistance welders .....................................................................................................66

3-8 Selecting an MCCB for capacitor circuit

3-8-1 Characteristics specific to capacitor circuits .................................................................69

3-9 MCCBs for semiconductor circuit

3-9-1 Faults and overcurrents in thyristor converters ...........................................................73
3-9-2 MCCB rated current ....................................................................................................74
3-9-3 Protecting thyristors from overcurrent .........................................................................75

3-10 Protecting SSCs using MCCBs or MMSs

3-10-1 For heater (resistive load) circuits ..............................................................................77
3-10-2 Motor circuits ..............................................................................................................78

3-11 Protecting inverter circuits using MCCBs

3-11-1 Inverter circuits ...........................................................................................................79

3-12 MCCBs for high frequency circuits ............................................................80

3-13 MCCBs for DC circuit applications .............................................................81
3-14 MCCBs for UPS applications .........................................................................83
3-15 MCCBs for servo amplifier applications ...................................................84
3-16 Ground fault protection in system applications
3-16-1 Grounding methods and ground fault protection in system applications ....................85

33
 Selection and application
3 3-1 Selection check points

3-1 Selection check points (10) Accessories

s 5NDERVOLTAGE TRIP s !UXILIARY SWITCH
When applying MCCBs to low-voltage circuits it is necessary
to consider their short-circuit breaking capacities, rated s 3HUNT TRIP s !LARM SWITCH
voltages, rated currents, installation details, protection s 0ADLOCKING s 4ERMINAL COVER
systems, wire sizes and type of load (motor, capacitor, s -ECHANICAL INTERLOCK DEVICE s %NCLOSURE
mercury arc lamp, etc.)
Fig. 3-1 illustrates points to be considered when selecting
MCCBs. These are listed in Table 3-1.
Fig. 3-1 Check points for selection
3-1-1 MCCB selection check points
1. Power supply system
(1) Power supply system
s $ISTRIBUTION SYSTEM TYPE.ETWORK
s 0OWER SUPPLY CAPACITY4RANSFORMER K6!
s 2EGULATION s !# OR $# Transformer
s &REQUENCY s ,INE VOLTAGE2ATED VOLTAGE
s #IRCUITS3INGLE PHASE  PHASE

(2) Location
s %NVIRONMENT CONDITIONS
s !MBIENT TEMPERATURE
2. Location

(3) Installation and connection 3. Installation and connection

s -OTOR CONTROL CENTER DISTRIBUTION BOARD 5. Short-circuit breaking capacity
s -AIN OR BRANCH
s &RONT MOUNTED FRONT CONNECTION 8. MCCB characteristics
s &RONT MOUNTED REAR CONNECTION 9. Operation
s &LUSH MOUNTED s 0LUG IN
s $RAW OUT s !RC SPACE CLEARANCE 10. Accessory
s -OUNTING ANGLE s 4ERMINATION

(4) Applications
s ,INE PROTECTION s -OTOR PROTECTION
s )NSTANTANEOUS TRIP s -ARINE USE
s 3PECIAL PURPOSE7ELDER CAPACITOR LIGHTS
6. Short-circuit current
(5) Short-circuit breaking capacity
7. Loads and wires
s &ULLY RATED s 3ELECTIVE TRIP
s #ASCADE BACKUP TRIP 8. Wire characteristics

(6) Short-circuit current

s -##" SERIES s &RAME SIZE

(7) Loads
s -##" RATED CURRENT s 7IRE SIZE BUS BARS 4. Application
s #URRENT TIME CHARACTERISTICS Load 7. Loads
8. Equipment characteristics

(8) Characteristics
s 7IRE AND LOAD EQUIPMENT
Mechanical and allowable thermal characteristics
s "REAKER
Breaking characteristics
Operation characteristics

(9) Operation
s 3WITCHING FREQUENCYOPERATING DURABILITY
s /PERATION METHOD
Remote – manual, motor driven
External operating handle (V and N)

34
 Selection and application
3-1 Selection check points
3

Table 3-1 Systematic MCCB selection

Check point Check points for system Check points for circuits Check points for MCCBs Specifications of MCCBs
designing and protective equipment

Power supply capacity Series

Total load capacity Short-circuit current Icu
Power supply system Frame size
Load voltage Power supply voltage Rated voltage (Ue)
(AC, DC, frequency)

No. of circuit wires No. of poles

Wires and equipment
Load current Wire size
connected in series
Series
Mechanical allowable Breaking characteristics
characteristics Frame size
Thermal allowable Operating Rated current (In)
characteristics characteristics

Load types Load current-time

characteristics
Line protection
Main circuit Protected equipment Types by use
Installed location types (Wires, loads) Motor protection
Branch circuit
Instantaneous trip type

Operation Switching Operating durability

frequency
Motor driven (M)
Operating method Operating device
(Remote, manual) External operating
Accessories
handle (V, N)

Shunt trip (F)

Undervoltage trip (R)
Auxiliary switch (W)
Installation and Switchboard construction Installation and
Alarm switch (K)
connection connection method
Front mounting,
front connection
Front mounting,
Line side or load side rear connection (X)
Power supply Selective trip
protective device Breaking Plug-in (P)
reliability coordination
Breaking characteristics
characteristics Operating
Operating characteristics
Economical use Cascade (back up) characteristics
trip coordination
Main MCCBs Allowable characteristics Operating
of load side protective characteristics
Series
devices
Frame size
Branch MCCBs Operating Allowable
characteristics of line characteristics Rated current (In)
side protective devices

35
 Selection and application
3 3-1 Selection check points

3-1-2 Selecting and MCCB ratings (3) Rated frequency

(1) Rated ultimate short-circuit breaking capacity MCCBs for AC application are rated for operation at both 50
(Icu) and 60Hz. If these MCCBs are used in circuits having other
frequencies, their operating performance, current carrying
A breaker must be selected that has a rated ultimate short-
capability, or breaking characteristics may be altered, and prior
circuit breaking capacity (Icu) higher than the short-circuit
verification is required. (Refer to page 80 3-12.)
current that passes through it. The short-circuit current will
When MCCBs are to be used for DC circuits, it is important
vary with transformer capacity as well as with the impedance
to ensure that the MCCBs are marked with “Acceptable DC
between the load and the MCCB.
circuits.” (Refer to page 81 3-13.)
Since a breaker should protect the load-end terminal and
protect against failures that occur near that terminal, it should
have a breaking capacity that is higher than the short-circuit
current at the load-end terminal.

(2) Rated current

The rated current of an MCCB is the maximum current
that can be continuously flowed through the MCCB without
problems, and should be higher than the maximum load
current expected in the circuit.
Select an MCCB with a rating that can carry a load current,
including transient currents, such as motor starting current,
and that can protect the cable and equipment from the
overcurrent.
The load current must not exceed the derated current
value when the MCCB is derated according to the following
environmental factors.
1. Effects of ambient temperature
MCCB performance conforms to the standard operating
conditions stipulated in IEC 60947-2. (For further details,
see Table 4-1.)
When the ambient temperature exceeds standard operating
conditions (−5 to 40°C), you must select an MCCB that
allows less load current to pass through the breaker.
2. Difference between the nominal rated current of the load
equipment and its actual value
3. Increase in the load current resulting from supply voltage
variations
4. Frequency variations (including waveform distortion)
5. Other

36
 Selection and application
3-1 Selection check points
3

3-1-3 Overcurrent protection principle 3-1-4 Protective coordination

Fig. 3-2 is a schematic diagram of a typical low-voltage When an overcurrent fault occurs, an overcurrent (overload
distribution system. The aim of overcurrent protection is to current or short-circuit current) flows from the power source
safeguard the system against overcurrent faults, to ensure to the fault point. In this situation it is essential to not only
high power-feeding reliability, and to establish an economical safeguard the system against the fault current but ensure
protecting system. system reliability and economics while keeping other systems
In the overload or intermediate overcurrent region, the least affected by the fault. A scheme of overcurrent protection
combination of a protective device and load equipment encompassing all of these considerations is called overcurrent
to be protected, such as motors including cables, must protective coordination.
be determined carefully. Generally, the combination is Generally, overcurrent protective coordination allows for the
determined by considering the protection characteristic curve following (Table 3-2):
of the protection device (MCCB) and the thermal damage s #OORDINATION BETWEEN THE PROTECTIVE DEVICE AND PROTECTED
characteristics of the equipment to be protected. As shown equipment
in Fig. 3-3, overcurrent protection is available in the region s 3ELECTIVE TRIP COORDINATION BETWEEN PROTECTIVE DEVICES
where the operating curve of the circuit breaker lies below s #ASCADE BACKUP TRIP COORDINATION BETWEEN PROTECTIVE
the thermal damage characteristics of the equipment to be devices
protected.
(1) Methods of coordination
Fig. 3-2 Typical low-voltage distribution system
It is important that the operating characteristics of the
Main power distribution board
Primary circuit
protective device (such as a circuit breaker or fuse) span
breaker the whole overcurrent range to safeguard the cable and load
Main circuit equipment. Reviews of both the overload current (overcurrent
breaker
Main circuit closer to the rated current) and the short-circuit current region
breaker Feeder
Bus bar are required.
Distribution Factors for consideration to ensure positive overcurrent
Bus bar board protection should include:
Power receiving and Feeder circuit s 3HORT CIRCUIT CURRENT AT THE POINT AT WHICH AN -##" IS TO BE
distribution room breaker installed
Branch circuit Branch circuit s $AMAGE CHARACTERISTICS OF THE WIRE IN THE OVERLOAD REGION
breaker s !LLOWABLE CURRENT AND ALLOWABLE )2t value of the wire at the
short-circuit time
s #URRENT TIME CHARACTERISTICS IN THE -##" OVERLOAD REGION
Fig. 3-3 Wiring and load protection using MCCBs (Overload and
s 2ATED SHORT CIRCUIT BREAKING CAPACITY OF THE -##"
intermediate overcurrent region)
s -AX BREAKING )2t value at the time of MCCB breaking
MCCB operating characteristics s &REEDOM FROM -##" MALFUNCTIONING CAUSED BY AMBIENT
conditions, starting characteristics of the load equipment,
a, b, c: Thermal damage characteristics
of wire and load equipment etc.
a, b: No and partial protection
c: Complete protection
Time

b c
a Protected region

Current

37
 Selection and application
3 3-1 Selection check points

Table 3-2 Low-voltage overcurrent protective coordination

Kind of coordination Coordination between the protective Coordination between protective devices
device and equipment to be protected
Selective trip coordination Cascade (backup) trip coordination
Objective Protecting equipment Improved power supply reliability Economical protective coordination
Description A protective device protects the wiring Protective devices on the line An economical circuit breaker with a small-
and load equipment against thermal side and the load side working in short-circuit breaking capacity is used,
and mechanical damage due to coordination prevent the short- with the short-circuit breaking of short-
overcurrents. circuit fault from extending from circuit currents higher than the rated short-
the fault circuit to other cables and circuit breaking capacity being undertaken
also minimize the scope of power by protective devices connected in series
failure. on the source line side.
Coordination condition s 3AFE BREAKING OF FAULT CURRENTS The load side protection device If a short-circuit current higher than the Icu
s 0ROTECTION OF WIRING AND LOAD completes current breaking over of the load side protection device flows,
equipment against thermal or the entire fault current range line side protection devices connected
mechanical damage. before the line side protection in series break the current, protecting
device is tripped, or before starting the load side protection device against
irreversible trip operation. expected thermal and mechanical
damages.
Protective device state Single or combined Combined Combined
Typical system
(indicating the
MCCB Solid-state trip MCCB
relationship of Fuse
coordination) (Protective device) type MCCB
Wiring
(Protected equipment)
Motor starter
(Protective device) MCCB
Fuse
MCCB MCCB

MCCB

M Motor
(Protected equipment)

The breaker away from the shorting point on the power supply Overcurrent protection method:
side must trip whenever short-circuit current occurs, but it must An overcurrent breaker operates on the principle that one
protect equipment from the thermal and mechanical stresses protective device alone will cut off short-circuit current passing
generated as short-circuit current passes through the circuit as through it. This is called a fully-rated system. When a single
well. This means the current peak value ipb and the let-through protective device is insufficient, then another breaker is
current ³ ib2dt at the time of MCCB breaking must be below the installed at the power supply side. This is called a cascade
allowable current peak value ipa of the protected equipment (backup) system, and it is often used to take advantage of
as well as the ³ ia2dt in the breaking characteristics of the more economical breaking method.
overcurrent protective device. In short, the following must be In an effort to ensure a more reliable power supply, only the
true. breaker on the power supply side that is closest to the fault
ipa > ipb, ³ ia2dt > ³ ib2dt point will trip when a short-circuit fault occurs at a branching
circuit such as a distribution system terminal. The operating
This point is especially important because breakers with
times must be coordinated between the breakers as a result
relatively low rated currents and higher short-circuit braking
so they will not track the breaker on the power supply side.
capacity are used more offen in today’s branch circuits.
This is known as selective trip coordination as opposed to the
fully-rated system. (Table 3-3)

Table 3-3 Low-voltage overcurrent protection systems

Protection system Purpose Features Protective device

Fully-rated system Selective tripping s #UTS OFF OVERCURRENT Improves the system's Combination
s 4HERMALLY AND power feeding reliability.
mechanically protects
Non-selective tripping wiring and load – Single or combination
Cascade (backup) system Non-selective tripping equipment across the Provides an economical Combination
entire overcurrent range. protection system.

38
 Selection and application
3-1 Selection check points
3

(2) Selective trip coordination (3) Cascade (backup) trip coordination

In the main circuit of facilities having a large power receiving Selective trip coordination requires that each protective
capacity or in systems containing an important load, selective device have a sufficient short-circuit breaking capacity (fully-
trip coordination should be used to provide improved power rated system). A fully-rated system, however, would not
feeding reliability. be economical to implement in large-capacity low-voltage
Selective trip coordination between protection devices ensure systems. An economic solution is cascade (backup) trip
that only the protection device located closest to a fault point coordination.
trips, and the line side protection devices remain closed. In cascade (backup) trip coordination, if a short-circuit current
In Fig. 3-4, for example, when a short-circuit fault occurs higher than the rated short-circuit breaking capacity of the load
at point F, only protection device PB is tripped. Line side side protection device flows, the line side protection devices
protection device PA is not unactuated thus allowing an connected in series break the current to protect the load side
uninterrupted supply of power to the normal circuits L1, L2, and protection device against thermal or mechanical damage.
L3. Either a current-limiting fuse or current-limiting circuit breaker
The device system configuration for selective trip coordination is used as the line side protection device.
must be such that the load side protection device completes Fig. 3-5 shows typical cascade trip coordination with a
the breaking of the fault current over the entire overcurrent distribution board circuit breaker backed up by a current-
range before the line side protection device is tripped, or limiting fuse.
before starting irreversible trip operation. The cascade (backup) system combines non-selective tripping
This condition must be met in both the overload current and systems for short-circuit current tripping, but short-circuit
the short-circuit current regions. failures that actually require backup occur only once every few
Selective trip coordination should be designed based on the years. Because the initial cost of installing the system is high,
overall system, but it is more commonly used in critical circuits however, an economical protective system designed using
or on key lines near the power supply. It is particularly backup coordination is a more sensible approach for general
important to coordinate between take-off circuit breakers circuits.
and branch MCCBs in spot network systems. It ensures the
take-off line will not be cut off when there is a terminal system Fig. 3-5 Cascade trip coordination
failure.
100
(min)

Fig. 3-4 Low-voltage power receiving system

10
Operating characteristic
of main circuit breaker
1
Operating time

PA 10

1.0
(sec)

0.1

PB 0.01
Operating characteristic
of branch circuit breaker
0.001
F 2 4 8 2 4 8 2 4 8
10 100 1000
L1 L2 L3 LX Current (A)
Region protected by branch Region protected by
circuit breaker main circuit breaker

39
 Selection and application
3 3-2 Cascade trip applications

3-2 Cascade trip applications 3-2-2 Criteria for cascade (backup) trip
coordination
3-2-1 Conditions for cascade (backup) trip
coordination Various breaker-based breaker-breaker or breaker-fuse
combinations suitable for backup have been reported.
A cascade (backup) system established between overcurrent However, testing and other standards are not well defined
circuit breakers can yield a very economical system as for backup protection at this point. Protective equipment
described in 3-1-4. combinations will have to be defined through uniform testing
When the main circuit breaker in a cascade (backup) system methods and criteria in order to ensure proper backup
has sufficient breaking capacity and trips quickly in the event protection with minimal confusion.
of a short-circuit fault, it can minimize the amount of energy Appendix A of IEC60947-2 stipulates protection coordination
passing through the branch MCCB. This depends on the standards for cascade (backup) systems. Table 3-4 shows
following conditions, however, which the main breaker alone criteria from that appendix.
or a branch MCCB connected in series with the main breaker
must satisfy: Table 3-4 Criteria for cascade (backup) systems (Appendix A of
(a) The peak let-through current must be kept below the IEC60947-2)
allowable mechanical strength limit of the branch MCCB. Item Items tested after the shorting test Criteria
IPL < IPA
1 Withstand voltage and insulation resistance Good
(b) The let-through I2t must be kept below the allowable
2 Contact welding Not welded
thermal strength limit of the branch MCCB.
³ i L 2dt < ³ i A 2dt 3 250% current tripping Good

(c) The arc energy generated in the branch breaker must be

kept below allowable limits for the branch MCCB.
³ e Li Ldt < ³ e Ai Adt
where
IPL: Peak let-through current (A)
³ i L 2dt: Let-through I2t (A2s)
³ e Li Ldt: Arc energy generated in the branch MCCB
IPA: Allowable through current peak value for the
branch MCCB
³ i A 2dt: Allowable I2t for the branch MCCB
³ e Ai Adt: Allowable arc energy for the branch MCCB
Condition (a) shows the effect the backup breaker has
on controlling current and it suggests that current-limiting
coordination of breakers is easier.
Condition (b) suggests that coordination is easier at each
current level as the time the current is on gets shorter. The
main breaker must trip at high speed in this case.
Condition (c) suggests that coordination is easier with less arc
energy passing through the branch MCCB
The amount of arc energy present with a short circuit is
determined by the short-circuit capacity of the system. If the
amount of arc energy present when the backup MCCB trips is
³eSiS dt, it yields the following equation.
³eSiS dt + ³eLiL dt = C (a constant)
It follows that ³eSiS dt should be as high as possible for easier
coordination. This suggests that a system with backup MCCBs
that have a faster contact opening time and higher arc voltage
is better. It also suggests that either a current-limiting fuse or
current-limiting circuit breaker is most appropriate for backup
coordination.

40
 Selection and application
3-2 Cascade trip applications
3

Tables 3-5 (a) and (b) show MCCB combination used for
cascade (backup) coordination.
Table 3-5 (a) Summary of combinations used for cascade (backup) coordination
230V AC
Branch circuit breaker Main BW BW BW BW BW BW BW BW BW BW BW BW BW BW BW BW BW BW
circuit 100 125 125 125 160 160 160 250 400 400 400 400 630 630 630 800 800 800
breaker EAG JAG RAG JAG EAG JAG RAG HAG EAG SAG RAG HAG EAG RAG HAG EAG RAG HAG
model BW BW BW
250 250 250
EAG JAG RAG
EW EW EW EW EW EW EW EW EW EW EW EW EW EW EW EW EW EW
100 125 125 125 160 160 160 250 400 400 400 400 630 630 630 800 800 800
EAG JAG RAG JAG EAG JAG RAG HAG EAG SAG RAG HAG EAG RAG HAG EAG RAG HAG
EW EW EW
250 250 250
EAG JAG RAG
MCCB ELCB Icu (kA) 25 50 100 125 36 50 100 125 50 85 100 125 50 100 125 50 100 125
(reference) sym
BW32AAG EW32AAG 2.5 5 10 10 10 5 7.5 7.5 7.5 – – – – – – – – – –
EW32EAG 2.5 5 10 10 10 5 7.5 7.5 7.5 – – – – – – – – – –
BW32SAG EW32SAG 5 22 50 60 60 10 30 30 30 – – – – – – – – – –
BW50AAG EW50AAG 2.5 5 10 10 10 5 7.5 7.5 7.5 – – – – – – – – – –
BW50EAG EW50EAG 5 22 50 60 60 10 30 30 30 – – – – – – – – – –
BW63EAG EW63EAG
BW50SAG EW50SAG 10 22 50 60 60 10 30 30 30 – – – – – – – – – –
BW63SAG EW63SAG
BW50RAG EW50RAG 25 – 50 85 85 36 50 50 50 35 50 50 50 42 50 50 42 50 50
BW63RAG EW63RAG
BW100AAG EW100AAG 5 22 50 60 60 10 30 30 30 – – – – – – – – – –
BW100EAG EW100EAG 25 – 50 85 85 36 50 50 50 35 50 50 50 35 50 50 35 50 50
BW125JAG EW125JAG 50 – – 100 100 – 50 100 100 50 85 85 85 50 85 85 50 85 85
BW125RAG EW125RAG 100 – – – – – – 100 100 – – 100 125 – 100 125 – 100 125
BW160EAG EW160EAG 36 – – – – – 50 60 60 42 50 50 50 42 42 50 42 50 50
BW250EAG EW250EAG
BW160JAG EW160JAG 50 – – – – – – 100 100 50 85 85 85 50 85 85 50 85 85
BW250JAG EW250JAG
BW160RAG EW160RAG 100 – – – – – – – – – – 100 125 – 100 125 – 100 125
BW250RAG EW250RAG
BW400EAG EW400EAG 50 – – – – – – – – – 85 85 100 50 85 85 50 85 85
BW400SAG EW400SAG 85 – – – – – – – – – – 100 125 – 100 125 – 100 125
BW400RAG EW400RAG 100 – – – – – – – – – – – 125 – 100 125 – 100 125
BW630EAG EW630EAG 50 – – – – – – – – – – – – – 85 100 50 85 100
BW630RAG EW630RAG 100 – – – – – – – – – – – – – – 125 – 100 125

41
 Selection and application
3 3-2 Cascade trip applications

Table 3-5 (b) Summary of combinations used for cascade (backup) coordination
400V AC
Branch circuit breaker Main BW BW BW BW BW BW BW BW BW BW BW BW BW BW BW BW BW BW
circuit 100 125 125 125 160 160 160 250 400 400 400 400 630 630 630 800 800 800
breaker EAG JAG RAG JAG EAG JAG RAG HAG EAG SAG RAG HAG EAG RAG HAG EAG RAG HAG
model BW BW BW
250 250 250
EAG JAG RAG
EW EW EW EW EW EW EW EW EW EW EW EW EW EW EW EW EW EW
100 125 125 125 160 160 160 250 400 400 400 400 630 630 630 800 800 800
EAG JAG RAG JAG EAG JAG RAG HAG EAG SAG RAG HAG EAG RAG HAG EAG RAG HAG
EW EW EW
250 250 250
EAG JAG RAG
MCCB ELCB Icu (kA) 10 30 50 65 18 30 50 65 30 36 50 70 36 50 70 36 50 125
(reference) sym
BW32SAG EW32SAG 2.5 10 10 15 15 10 10 10 10 – – – – – – – – – –
BW50EAG EW50EAG 2.5 10 10 15 15 10 10 10 10 – – – – – – – – – –
BW63EAG EW63EAG
BW50SAG EW50SAG 7.5 10 10 15 15 10 10 10 10 – – – – – – – – – –
BW63SAG EW63SAG
BW50RAG EW50RAG 10 – 25 42 42 15 25 30 30 20 20 20 20 14 14 14 14 14 14
BW63RAG EW63RAG
BW100EAG EW100EAG 10 – 25 42 42 18 25 30 30 14 14 14 14 14 14 14 14 14 14
BW125JAG EW125JAG 30 – – 50 50 – 30 50 50 30 36 36 65 36 36 65 36 36 65
BW125RAG EW125RAG 50 – – – – – – – – – – 50 70 – 50 70 – 50 70
BW160EAG EW160EAG 18 – – – – – 25 30 30 30 30 30 42 18 25 25 18 25 25
BW250EAG EW250EAG
BW160JAG EW160JAG 30 – – – – – – – – 30 36 36 65 36 36 65 36 36 65
BW250JAG EW250JAG
BW160RAG EW160RAG 50 – – – – – – – – – – 50 70 – 50 70 – 50 70
BW250RAG EW250RAG
BW400EAG EW400EAG 30 – – – – – – – – – 30 35 65 30 35 65 30 35 65
BW400SAG EW400SAG 36 – – – – – – – – – – 50 70 36 50 70 36 50 70
BW400RAG EW400RAG 50 – – – – – – – – – – – 70 – 50 70 – 50 70
BW630EAG EW630EAG 36 – – – – – – – – – – – – – 42 65 36 42 65
BW630RAG EW630RAG 50 – – – – – – – – – – – – – – – – 50 70

42
 Selection and application
3-3 Selective trip applications
3

3-3 Selective trip applications

3-3-1 Selective trip coordination of breakers When a breaker with ternary trip-element characteristics
having a short-time delay trip element is used on the power
Selective tripping is coordinated between the breaker on the
supply side, selective trip coordination is much better than with
power supply side and the one on the load side by setting
general-used breakers because the allowable short-time delay
the maximum breaking time for the branch breaker on the
is between 0.1 and 0.5 second.
load side below the relay time characteristics of the breaker
Tables 3-6 (a), (b), (c), and (d) show possible breaker
on the power supply side. However, it may not be possible to
combinations used in selective trip coordination. Coordination
coordinate selective tripping in some instances because the
is much better if current-limiting breakers are used on the load
breaker on the power supply side may have instantaneous
side because of their current limiting capabilities.
characteristics as well. (See Fig. 3-6.)

Fig. 3-6 Selective tripping characteristic, MCCB – MCCB

Main MCCB
(Ternary trip-element)

Ternary trip-element MCCB

Branch MCCB
Time

Branch MCCB
(Load side)
Relay time

Current
Range with protective Range with no protective
coordination coordination

43
 Selection and application
3 3-3 Selective trip applications

Table 3-6 (a) Selective trip coordination

AC230V MCCB [Unit : kA]
Main circuit BX100HAE BX160HAE BX250HAE BX400HAE BX630HAE BX800HAE BX1000HAE BX1250HAE BX1600HAE
breaker
Protective Ternary trip-element (long-time delay, short-time delay, instantaneous)
characteristics
In [A] 40 100 160 250 400 630 800 1000 1250 1600
Control unit 5 5 5 5 5 5 5 5 5 5
Icu [kA] (sym) 100 100 100 100 100 100 85 85 85 85
BW32AAG BW50AAG 2.5 0.5 1.2 2.0 2.5 2.5 2.5 2.5 2.5 2.5 2.5
BW50EAG BW63EAG 5 0.5 1.2 2.0 2.5 4.0 5 5 5 5 5
BW100AAG 5 1.2 2.0 2.5 4.0 5 5 5 5 5
BW100EAG 25 1.2 2.0 2.5 4.0 5.8 25 25 25 25
BW250EAG 36 2.0 2.5 4.0 5.8 36 36 36 36
BW400EAG 50 4.0 5.8 50 50 50 50
BW630EAG 50 5.8 50 50 50 50
BW800EAG 50 50 50 50 50
BW32SAG 5 0.5 1.2 2.0 2.5 4.0 5 5 5 5 5
BW50SAG BW63SAG 10 0.5 1.2 2.0 2.5 4.0 5.8 10 10 10 10
BW125JAG 50 0.5 1.2 2.0 2.5 4.0 5.8 50 50 50 50
BW250JAG 50 2.0 2.5 4.0 5.8 50 50 50 50
BW400SAG 85 4.0 5.8 85 85 85 85
BW50RAG BW63RAG 25 0.5 1.2 2.0 2.5 4.0 5.8 25 25 25 25
BW125RAG 100 0.5 1.2 2.0 2.5 4.0 5.8 85 85 85 85
BW250RAG 100 2.0 2.5 4.0 5.8 85 85 85 85
BW400RAG 100 4.0 5.8 85 85 85 85
BW630RAG 100 5.8 85 85 85 85
BW800RAG 100 85 85 85 85
BW50HAG 125 0.5 1.2 2.0 2.5 4.0 5.8 85 85 85 85
BW125HAG 125 0.5 1.2 2.0 2.5 4.0 5.8 85 85 85 85
BW250HAG 125 2.0 2.5 4.0 5.8 85 85 85 85
BW400HAG 125 4.0 5.8 85 85 85 85
BW630HAG 125 5.8 85 85 85 85
BW800HAG 125 85 85 85 85
BX100HAE 100 85 85 85 85 85 85 85 85 85 85
BX160HAE 100 85 85 85 85 85 85 85 85
BX250RAE 90 85 85 85 85 85 85 85
BX250HAE 100 85 85 85 85 85 85 85
BX400RAE 85 85 85 85 85 85 85
BX400HAE 100 85 85 85 85 85 85
BX630RAE 85 85 85 85 85 85
BX630HAE 100 85 85 85 85 85

44
 Selection and application
3-3 Selective trip applications
3

AC440V MCCB [Unit : kA]

Main circuit BX100HAE BX160HAE BX250HAE BX400HAE BX630HAE BX800HAE BX1000HAE BX1250HAE BX1600HAE
breaker
Protective Ternary trip-element (long-time delay, short-time delay, instantaneous)
characteristics
In [A] 40 100 160 250 400 630 800 1000 1250 1600
Control unit 5 5 5 5 5 5 5 5 5 5
Icu [kA] (sym) 65 65 65 65 65 65 65 65 65 65
BW32AAG BW50AAG 1.5 0.3 0.8 1.4 1.5 1.5 1.5 1.5 1.5 1.5 1.5
BW50EAG BW63EAG 2.5 0.3 0.8 1.4 2.5 2.5 2.5 2.5 2.5 2.5 2.5
BW100EAG 10 1.2 2.0 2.5 4.0 5.8 10 10 10 10
BW250EAG 18 2.0 2.5 4.0 5.8 18 18 18 18
BW400EAG 30 4.0 5.8 30 30 30 30
BW630EAG 36 5.8 36 36 36 36
BW800EAG 36 36 36 36 36
BW32SAG 2.5 0.5 1.2 2.0 2.5 2.5 2.5 2.5 2.5 2.5 2.5
BW50SAG BW63SAG 7.5 0.5 1.2 2.0 2.5 4.0 5.8 7.5 7.5 7.5 7.5
BW125JAG 30 0.5 1.2 2.0 2.5 4.0 5.8 30 30 30 30
BW250JAG 30 2.0 2.5 4.0 5.8 30 30 30 30
BW400SAG 36 4.0 5.8 36 36 36 36
BW50RAG BW63RAG 10 0.5 1.2 2.0 2.5 4.0 5.8 10 10 10 10
BW125RAG 50 0.5 1.2 2.0 2.5 4.0 5.8 50 50 50 50
BW250RAG 50 2.0 2.5 4.0 5.8 50 50 50 50
BW400RAG 50 4.0 5.8 50 50 50 50
BW630RAG 50 5.8 50 50 50 50
BW800RAG 50 50 50 50 50
BW50HAG 65 0.5 1.2 2.0 2.5 4.0 5.8 65 65 65 65
BW125HAG 65 0.5 1.2 2.0 2.5 4.0 5.8 65 65 65 65
BW250HAG 65 2.0 2.5 4.0 5.8 65 65 65 65
BW400HAG 70 4.0 5.8 65 65 65 65
BW630HAG 70 5.8 65 65 65 65
BW800HAG 70 65 65 65 65
BX100HAE 65 65 65 65 65 65 65 65 65 65 65
BX160HAE 65 65 65 65 65 65 65 65 65
BX250RAE 50 50 50 50 50 50 50 50
BX250HAE 65 65 65 65 65 65 65 65
BX400RAE 42 42 42 42 42 42 42
BX400HAE 65 65 65 65 65 65 65
BX630RAE 42 42 42 42 42 42
BX630HAE 65 65 65 65 65 65

45
 Selection and application
3 3-3 Selective trip applications

Table 3-6 (a) Selective trip coordination

AC230V ELCB [Unit : kA]
Main circuit BX100HAE BX160HAE BX250HAE BX400HAE BX630HAE BX800HAE BX1000HAE BX1250HAE BX1600HAE
breaker
Protective Ternary trip-element (long-time delay, short-time delay, instantaneous)
characteristics
In [A] 40 100 160 250 400 630 800 1000 1250 1600
Control unit 5 5 5 5 5 5 5 5 5 5
Icu [kA] (sym) 100 100 100 100 100 100 85 85 85 85
EW32AAG EW50AAG 2.5 0.5 1.2 2.0 2.5 2.5 2.5 2.5 2.5 2.5 2.5
EW32EAG 2.5 0.5 1.2 2.0 2.5 2.5 2.5 2.5 2.5 2.5 2.5
EW50EAG EW63EAG 5 0.5 1.2 2.0 2.5 4.0 5 5 5 5 5
EW100AAG 5 1.2 2.0 2.5 4.0 5 5 5 5 5
EW100EAG 25 1.2 2.0 2.5 4.0 5.8 25 25 25 25
EW250EAG 36 2.0 2.5 4.0 5.8 36 36 36 36
EW400EAG 50 4.0 5.8 50 50 50 50
EW630EAG 50 5.8 50 50 50 50
EW800EAG 50 50 50 50 50
EW32SAG 5 0.5 1.2 2.0 2.5 4.0 5 5 5 5 5
EW50SAG EW63SAG 10 0.5 1.2 2.0 2.5 4.0 5.8 10 10 10 10
EW125JAG 50 0.5 1.2 2.0 2.5 4.0 5.8 50 50 50 50
EW250JAG 50 2.0 2.5 4.0 5.8 50 50 50 50
EW400SAG 85 4.0 5.8 85 85 85 85
EW50RAG EW63RAG 25 0.5 1.2 2.0 2.5 4.0 5.8 25 25 25 25
EW125RAG 100 0.5 1.2 2.0 2.5 4.0 5.8 85 85 85 85
EW250RAG 100 2.0 2.5 4.0 5.8 85 85 85 85
EW400RAG 100 4.0 5.8 85 85 85 85
EW630RAG 100 5.8 85 85 85 85
EW800RAG 100 85 85 85 85
EW50HAG 125 0.5 1.2 2.0 2.5 4.0 5.8 85 85 85 85
EW125HAG 125 0.5 1.2 2.0 2.5 4.0 5.8 85 85 85 85
EW250HAG 125 2.0 2.5 4.0 5.8 85 85 85 85
EW400HAG 125 4.0 5.8 85 85 85 85
EW630HAG 125 5.8 85 85 85 85
EW800HAG 125 85 85 85 85

46
 Selection and application
3-3 Selective trip applications
3

AC440V ELCB [Unit : kA]

Main circuit BX100HAE BX160HAE BX250HAE BX400HAE BX630HAE BX800HAE BX1000HAE BX1250HAE BX1600HAE
breaker
Protective Ternary trip-element (long-time delay, short-time delay, instantaneous)
characteristics
In [A] 40 100 160 250 400 630 800 1000 1250 1600
Control unit 5 5 5 5 5 5 5 5 5 5
Icu [kA] (sym) 65 65 65 65 65 65 65 65 65 65
EW32EAG 1.5 0.3 0.8 1.4 1.5 1.5 1.5 1.5 1.5 1.5 1.5
EW50EAG EW63EAG 2.5 0.3 0.8 1.4 2.5 2.5 2.5 2.5 2.5 2.5 2.5
EW100EAG 10 1.2 2.0 2.5 4.0 5.8 10 10 10 10
EW250EAG 18 2.0 2.5 4.0 5.8 18 18 18 18
EW400EAG 30 4.0 5.8 30 30 30 30
EW630EAG 36 5.8 36 36 36 36
EW800EAG 36 36 36 36 36
EW32SAG 2.5 0.5 1.2 2.0 2.5 2.5 2.5 2.5 2.5 2.5 2.5
EW50SAG EW63SAG 7.5 0.5 1.2 2.0 2.5 4.0 5.8 7.5 7.5 7.5 7.5
EW125JAG 30 0.5 1.2 2.0 2.5 4.0 5.8 30 30 30 30
EW250JAG 30 2.0 2.5 4.0 5.8 30 30 30 30
EW400SAG 36 4.0 5.8 36 36 36 36
EW50RAG EW63RAG 10 0.5 1.2 2.0 2.5 4.0 5.8 10 10 10 10
EW125RAG 50 0.5 1.2 2.0 2.5 4.0 5.8 50 50 50 50
EW250RAG 50 2.0 2.5 4.0 5.8 50 50 50 50
EW400RAG 50 4.0 5.8 50 50 50 50
EW630RAG 50 5.8 50 50 50 50
EW800RAG 50 50 50 50 50
EW50HAG 65 0.5 1.2 2.0 2.5 4.0 5.8 65 65 65 65
EW125HAG 65 0.5 1.2 2.0 2.5 4.0 5.8 65 65 65 65
EW250HAG 65 2.0 2.5 4.0 5.8 65 65 65 65
EW400HAG 70 4.0 5.8 65 65 65 65
EW630HAG 70 5.8 65 65 65 65
EW800HAG 70 65 65 65 65

47
 Selection and application
3 3-3 Selective trip applications

3-3-2 Selective trip coordination between Fig. 3-7 PF·S high-voltage power receiving facility
MCCBs and high-voltage side protective
devices VCT

(1) Coordination between MCCBs and power fuses LBS with power fuse (PF)

In type PF·S high-voltage power receiving facilities like

those shown in Fig. 3-7, power fuses (PF) are often used as
3øT 3øT 1øT SC
protective devices. Power fuses are also used to protect the
primary circuit of a transformer as shown in Fig. 3-8.
In these types of facility, selective trip coordination must
be maintained between the PF and the MCCB installed
on the transformer secondary circuit. Without selective trip
MCCB MCCB MCCB
coordination between the PF and the MCCB, faults occurring
on the load side of the MCCB will trip the PF, causing a total
system shutdown.
To establish selective trip coordination between the PF
Fig. 3-8 PF high-voltage power receiving facility
and MCCB, the following condition must be satisfied: when
the allowable current-time characteristic curve of the PF is
DS
superimposed on the operating characteristic curve of the
MCCB as shown in Fig. 3-9 (by converting the current of the
PF to the low voltage side, or the current of the MCCB to the PF
high-voltage side), these curves do not cross.
Fig. 3-9 shows the operating characteristics of the MCCB
converted to the high-voltage side (transformer primary side). T
Conversion to the high-voltage side is done by dividing the
current in the operating characteristic curve of the MCCB by
the voltage ratio of the transformer. (50, if 20kV/400V) MCCB
Conversion to the low-voltage side is done by multiplying the
current value in the allowable current time characteristic curve
of the PF by the same voltage ratio. MCCB MCCB MCCB
Because the maximum rated current of a PF is limited by the
conditions stated below, to achieve selective trip coordination,
it is necessary to reduce the current rating of the MCCB, or to
select an MCCB with an adjustable instantaneous trip current Fig. 3-9 MCCB – PF selective trip coordination
feature.
Power fuse
(a) Conditions for selecting PF current rating: (allowable current-time
s Selective tripping can be coordinated with upstream power characteristic)
fuse protective devices.
Operating time

s ! SHORT CIRCUIT CURRENT  TIMES HIGHER THAN THE TRANSFORMER MCCB trip
current rating can be interrupted within 2 seconds to protect characteristic Short-circuit current
the transformer. Sometimes, an MCCB may be substituted (transformer
for the PF to provide this function. secondary side)
s $EGRADATION OF THE 0& DUE TO TRANSFORMER EXCITATION INRUSH
current can be prevented.
Table 3-7 lists the applicable combinations of FUJI MCCBs
Current
and FUJI high-voltage current-limiting fuses from the
standpoint of selective trip coordination. (Converted to transformer primary side)

48
 Selection and application
3-3 Selective trip applications
3

3-3-3 Selective trip coordination with a high-voltage fuse

This section describes selective trip coordination for a transformer primary-side high-voltage fuse and a High-voltage fuse
JC type
secondary-side molded case circuit breaker or earth leakage circuit breaker. The applicable range, however,
is within the short-circuit current determined by the transformer capacity and percentage of impedance for Transformer
6/0.42kV
the breaking capacity of the molded case circuit breaker or earth leakage circuit breaker. (Use caution for
the ranges marked with an asterisk (*).) This gives the secondary short-circuit current that is assumed to
MCCB
have an impedance percentage of 4% of the transformer depending on the conditions of short-circuit current
calculation.

Capacity (kVA) 100 200 300 500 750 1000

Secondary current (A) 137 275 412 687 1031 1375
Secondary short-circuit current (kA) 3.4 6.9 10.3 17.2 25.8 34.4
JC type power fuse rated current (A) 20 30 50 60 75 100
CB breaking
MCCB type ELCB type CB rated current (A)
capacity (kA)
BW32AAG– (2,3)P EW32EAG–3P 1.5 5 to 32
BW50AAG– (2,3)P EW50AAG– (2,3)P 5 to 50
BW32SAG– (2,3)P EW32SAG–3P 2.5 3, 5 to 32
BW50EAG– (2,3)P EW50EAG–3P 5 to 50
BW63EAG– (2,3)P EW63EAG–3P 60, 63
BW50SAG– (2,3)P EW50SAG–3P 7.5 5 to 32
BW63SAG– (2,3)P EW63SAG–3P 60, 63
BW50RAG– (2,3)P EW50RAG–3P 10 10 to 50
BW63RAG– (2,3)P EW63RAG–3P 60, 63
BW100EAG– (2,3)P EW100EAG–3P 50, 60, 63, 75, 100
BW125JAG– (2,3)P EW125JAG– (3,4)P 30 15 to 75
BW125RAG– (2,3)P EW125RAG– (3,4)P 50
BW125JAG– (2,3)P EW125JAG– (3,4)P 30 100 to 125
BW125RAG– (2,3)P EW125RAG– (3,4)P 50
BW250EAG– (2,3)P EW250EAG–3P 18 125
BW250JAG– (2,3,4)P EW250JAG– (3,4)P 30
BW250RAG– (2,3,4)P EW250RAG– (3,4)P 50
BW250EAG– (2,3)P EW250EAG–3P 18 150 to 250
BW250JAG– (2,3,4)P EW250JAG– (3,4)P 30
BW250RAG– (2,3,4)P EW250RAG– (3,4)P 50
BW400EAG– (2,3)P EW400EAG–3P 30 250
BW400SAG– (2,3)P EW400SAG–3P 36
BW400RAG– (2,3,4)P EW400RAG– (3,4)P 50
BW400HAG– (2,3,4)P EW400HAG– (3,4)P 70
BW400EAG– (2,3)P EW400EAG–3P 30 300
BW400SAG– (2,3)P EW400SAG–3P 36
BW400RAG– (2,3,4)P EW400RAG– (3,4)P 50
BW400HAG– (2,3,4)P EW400HAG– (3,4)P 70
BW400EAG– (2,3)P EW400EAG–3P 30 350, 400
BW400SAG– (2,3)P EW400SAG–3P 36
BW400RAG– (2,3,4)P EW400RAG– (3,4)P 50
BW400HAG– (2,3,4)P EW400HAG– (3,4)P 70
BW630EAG–3P EW630EAG–3P 36 500, 600, 630
BW630RAG–3P EW630RAG–3P 50
BW630HAG–3P EW630HAG–3P 70
BW800EAG–3P EW800EAG–3P 36 700, 800
BW800RAG–3P EW800RAG–3P 50
BW800HAG–3P EW800HAG–3P 70
Note: 2 or 3 poles are entered for (2, 3), 3 or 4 poles are entered for (3, 4) and 2, 3 or 4 poles are entered for (2, 3, 4). The 3-pole 30A molded-case circuit breaker is
described as BW50AAG–3P030. The rated current described as “3A” is the rating applicable to a molded-case circuit breaker only.

49
 Selection and application
3 3-3 Selective trip applications

Table 3-7 (b) Selective trip coordination between MCCB and 24kV power fuse
Transformer Capacity (kVA) 50 75 100 125 160 200 250 315 400 500 630 800 1,000 1,250 1,600 2,000
Primary current (A) 1.5 2.2 2.9 3.6 4.7 5.8 7.3 9.2 11.6 14.5 18.2 23.1 29 36 46.5 58
Secondary current (A) 72 108 144 180 230 290 360 455 576 720 910 1,160 1,440 1,800 2,300 2,890
% impedance (%) 4 4 4 4 4 4 4 4 4 4 4 5 5 5 5 5
Primary short-circuit current when 36 54 72 90 115 145 180 228 288 360 455 464 576 720 920 1,156
the secondary side of the transformer
shorts (A)
Secondary short-circuit current (kA) 1.8 2.7 3.6 4.5 5.8 7.3 9.0 11.4 14.4 18.0 22.8 23.2 28.8 36.0 46.0 57.8
Primary PF. Rated current 6 6 10 10 16 16 25 25 32 40 50 63 63 80 80 80
DIN/VDE 0670 Part 402(A)
Series MCCB type Breaking capacity MCCB Rated Note 1 Selective trip coordination is not available.
Icu/Ics (kA) current Note 2 Selective trip coordination is available. (Instantaneous trip current must be adjusted
400V IEC 60947-2 (A) for coordination.)
Note 3 Selective trip coordination is available. Make sure however that the short-circuit
current where the MCCB is installed is less than its breaking capacity.
Note 4 Selective trip coordination is available.
AAG BW32 1.5/1 3, 5, 10, 15, 20 Note 3
30, 32
BW50 1.5/1 5, 10, 15, 20, 30 Note 3
32, 40, 50
BW100 1.5/1 60, 63, 75, 100 Note 3
EAG BW50 2.5/2 5, 10, 15, 20, 30 Note 4 Note 3
32, 40, 50
BW63 2.5/2 60, 63 Note 4 Note 3
BW100 10/5 50, 60, 63, 75 Note 4 Note 3
100
BW160 18/9 125 Note 1 Note 4 Note 3
150, 160 Note 1 Note 4 Note 3
BW250 18/9 175, 200 Note 1 Note 4 Note 3
225, 250 Note 1 Note 4 Note 3
BW400 30/15 250 Note 1 Note 4 Note 3
300, 350 Note 1 Note 4 Note 3
400 Note 1 Note 4 Note 3
BW630 36/18 500, 600, 630 Note 1 Note 4 Note 3
BW800 36/18 700 Note 1 Note 4 Note 3
800 Note 1 Note 4 Note 3
JAG BW125 30/15 15, 20, 30, 40, 50 Note 4 Note 3
60
75, 100, 125 Note 1 Note 4 Note 3
BW160 30/15 125 Note 1 Note 4 Note 3
150, 160 Note 1 Note 4 Note 3
BW250 30/15 175, 200 Note 1 Note 4 Note 3
225, 250 Note 1 Note 4 Note 3
SAG BW32 2.5/2 3, 5, 10, 15, 20 Note 4 Note 3
30, 32
BW50 7.5/4 5, 10, 15, 20, 30 Note 4 Note 3
32, 40, 50
BW63 7.5/4 60, 63 Note 4 Note 3
BW125 36/18 15, 20, 30, 40, 50 Note 4 Note 3
60
75, 100, 125 Note 1 Note 4 Note 3
BW160 36/18 125 Note 1 Note 4 Note 3
150, 160 Note 1 Note 4 Note 3
BW250 36/18 175, 200 Note 1 Note 4 Note 3
225, 250 Note 1 Note 4 Note 3
BW400 36/18 250 Note 1 Note 4 Note 3
300, 350 Note 1 Note 4 Note 3
400 Note 1 Note 4 Note 3

50
 Selection and application
3-3 Selective trip applications
3

Table 3-7 (b) Selective trip coordination between MCCB and 24kV power fuse (Continued)
Transformer Capacity (kVA) 50 75 100 125 160 200 250 315 400 500 630 800 1,000 1,250 1,600 2,000
Primary current (A) 1.5 2.2 2.9 3.6 4.7 5.8 7.3 9.2 11.6 14.5 18.2 23.1 29 36 46.5 58
Secondary current (A) 72 108 144 180 230 290 360 455 576 720 910 1,160 1,440 1,800 2,300 2,890
% impedance (%) 4 4 4 4 4 4 4 4 4 4 4 5 5 5 5 5
Primary short-circuit current when 36 54 72 90 115 145 180 228 288 360 455 464 576 720 920 1,156
the secondary side of the transformer
shorts (A)
Secondary short-circuit current (kA) 1.8 2.7 3.6 4.5 5.8 7.3 9.0 11.4 14.4 18.0 22.8 23.2 28.8 36.0 46.0 57.8
Primary PF. Rated current 6 6 10 10 16 16 25 25 32 40 50 63 63 80 80 80
DIN/VDE 0670 Part 402(A)
Series MCCB type Breaking capacity MCCB Rated Note 1 Selective trip coordination is not available.
Icu/Ics (kA) current Note 2 Selective trip coordination is available. (Instantaneous trip current must be adjusted
400V IEC 60947-2 (A) for coordination.)
Note 3 Selective trip coordination is available. Make sure however that the short-circuit
current where the MCCB is installed is less than its breaking capacity.
Note 4 Selective trip coordination is available.
RAG BW50 10/5 10, 15, 20, 30, 32 Note 4 Note 3
40, 50
BW63 10/5 60, 63 Note 4 Note 3
BW125 50/25 15, 20, 30, 40, 50 Note 4 Note 3
60
75, 100, 125 Note 1 Note 4 Note 3
BW160 50/25 125 Note 1 Note 4 Note 3
150, 160 Note 1 Note 4 Note 3
BW250 50/25 175, 200 Note 1 Note 4 Note 3
225, 250 Note 1 Note 4 Note 3
BW400 50/25 250 Note 1 Note 4 Note 3
300, 350 Note 1 Note 4 Note 3
400 Note 1 Note 4 Note 3
BW630 50/25 500, 600, 630 Note 1 Note 4 Note 3
BW800 50/25 700 Note 1 Note 4 Note 3
800 Note 1 Note 4 Note 3
HAG BW50 65/17 15, 20, 30, 32, 40 Note 4
50
BW125 65/17 15, 20, 30, 40, 50 Note 4
60
75, 100, 125 Note 1 Note 4
BW250 65/17 125 Note 1 Note 4
150, 160, 175 Note 1 Note 4
200
225, 250 Note 1 Note 4
BW400 70/35 250 Note 1 Note 4
300, 350 Note 1 Note 4
400 Note 1 Note 4
BW630 70/35 500, 600, 630 Note 1 Note 4
BW800 70/35 700 Note 1 Note 4
800 Note 1 Note 4

51
 Selection and application
3 3-4 Wiring protection

3-4 Wiring protection

3-4-1 Description R0 (1+DT) i2dt=JMCdT
Wiring must be protected against the heat generated by
transforms as i2dt= S2 × 1 dT , where k2= Dp
2
overcurrents. When a circuit fault occurs, the overload or short- k 1 +T JCG
circuit current flowing into the fault point generates heat in the D
1 +T
wire to raise the wire temperature. While the wire temperature
and i2t=∫i2dt= S
2 T
∫ 1 dT= S22 loge D
is below the allowable temperature of the wire, the protective k2 0 1 +T k 1 +T0
device must interrupt the overcurrent to protect the wire. D D
The allowable temperature of the wire depends on the material 2 234+T
i t=5.05 loge 234+T0 ×10 4
×S 2

of the wire insulation. The highest temperature that the

i2t≈1.4×104S2
insulation can tolerate is designated the allowable temperature
of the wire. Conductor temperature following a short circuit
Since the temperature rise in the wire associated with k2 2
2i t 1
heat can be translated into a current-time characteristic, a T1= 1
D +T0 eS − D
comparison of this characteristic with the current interrupting
characteristic of circuit breakers will help determine the The following equation holds based solely on temperature rise.
amount of protection. k2 2
2i t
Protection in the overload region can be generally discussed T1= 1
D +T0 eS −1
with reference to a current-time characteristic diagram (see
Fig. 3-3); protection in the short-circuit region is discussed where
in numeric terms with no allowance made for heat radiation. R0: Conductor resistance (:/cm)
Either way, the basic idea is to interrupt the overcurrent before D: Temperature coefficient of the conductor resistor,
the wire is heated above its allowable temperature. 4.27u10−3 (1/°C)
T: Conductor temperature due to short circuit, 160 (°C)
T0: Conductor temperature before short circuit, 70 (°C)
3-4-2 Thermal characteristics of wire T1: Rise in conductor temperature (K)
The temperature rise of wires due to overcurrent depends on J: Mechanical equivalent of heat, 4.19 (J/cal)
the let-through current and the continuous current carrying M: Conductor mass, 8.93 (g/cm3)
time. The relationship between the temperature rise and the C: Specific heat of the conductor, 0.092 (J/cm3°C)
allowable current is classified in three modes: continuous, G: Specific gravity of the conductor, 8.93 (g/cm3)
short-time, and short-circuit. p: Specific resistance of the conductor, 1.6u10−6 (:/cm)
The allowable temperature limits of PVC insulated wires S: Conductor cross section (mm2)
typically used in low-voltage circuits are prescribed to be 70°C I2t: Current squared time (A2s)
(continuous), 100°C (short-time), and 160°C (short-circuit), The equation above suggests that temperature rise in the
respectively. conductor (wire) is determined by the let-through I2t.
Since heat radiation is negligible at the time of a short circuit,
the short-circuit protection of the wiring can be determined by Fig. 3-11 shows this relationship, while Table 3-9 (a) shows
comparing the maximum breaking I2t value of the protective allowable I2t when there is a short circuit.
device and the allowable I2t value of the wire.

Fig. 3-11 Temperature rise in PVC insulated conductors due to let-through I2t
1000
800

600
500
400

300

200
Temperature rise (K)

300

500
400

630
240
185
120
2.5
1.5

150
35
10

16

25

50
4

95
6

70
1

100 Wire sizes (mm2)

80

60
50
40

30

20

10
0.01 0.05 0.1 0.5 1 5 10 50 100 500 1000 5000 10000 100000
Let-through I2t (×106A2s)
52
 Selection and application
3-4 Wiring protection
3

Table 3-9 (a) Current squared time i2t=5.05 loge((234+T)/(234+T0)uS2u104

IEC wiring values JIS wiring values (Reference)

6 2
Wire cross section (S) Current squared time (u10 A s) Wire cross section (S) Current squared time (u106A2s)
(mm2) (mm2)
Starting at 70°C (i2t) Starting at 30°C (i2t) Starting at 60°C (i2t) Starting at 30°C (i2t)
1 0.013 0.020 2 0.054 0.076
1.5 0.029 0.045 3.1 0.133 0.187
2.5 0.082 0.126 3.5 0.165 0.232
4 0.210 0.324 5.5 0.408 0.572
6 0.471 0.728 8 0.863 1.21
10 1.31 2.02 14 2.64 3.71
16 3.35 5.18 22 6.53 9.16
25 8.18 12.6 30 12.1 17.0
35 16.0 24.8 38 19.5 27.3
50 32.7 50.6 50 33.7 47.3
70 64.2 99.1 60 48.6 68.1
95 118 182 80 86.3 121
120 189 291 100 135 189
150 295 455 125 211 296
185 448 692 150 303 426
240 754 1165 200 539 757
300 1179 1820 250 843 1183
400 2095 3235 325 1425 1999
500 3274 5055 400 2158 3028
630 5198 8025 500 3372 4731

Table 3-9 (b) Conductor specifications The relationship of current to the rise in conductor temperature
in the continuous and short-time regions makes heat
Resistor temperature coefficient D 0.00427 (1/°C)
1/D 234 (°C) dissipation too important to ignore, yet it varies with conditions
like the type of installation. Although this is not impossible to
Initial conductor temperature * T0 IEC wiring: 70°C
calculate, it is not commonly done. IEC standards stipulate
JIS wiring: 60°C
allowable current for insulated wiring in the continuous region
Ultimate conductor temperature * T IEC wiring: 160°C using an ambient temperature of 30°C and a rise in conductor
JIS wiring: 150°C
temperature of 40°C.
Specific conductor resistance U 0.0000016 (:cm) The IEEE uses a minimum of 20s for the short-time region
Mechanical equivalent of heat J 4.19 (J/cal) where a conductor temperature as high as 100°C is allowable.
This temperature is sustainable in the conductor because of
Specific heat of the conductor C 0.092 (J/cm3°C)
the inverse time-delay trip time of the breaker. Fig. 3-12 shows
Specific gravity of the conductor V 8.93 (g/cm3) current-time characteristics for 600V PVC-insulated wiring
K2=Dp/JCV 1.985E–09 where conductor temperatures reach 100°C starting from
no-load conditions at an ambient temperature for the wiring of
Note: * Ambient temperature: 30°C 30°C.

Fig. 3-12 Current-time characteristics in which 600V PVC insulated conductors reach a temperature of 100°C (rise of 70°C)
1000
800
600
500
400
300

200

100
Wire sizes (mm2)
60
630
Time (sec)

500
400

50
300
240
185
150

40
120
95
70
50

30
35
25
16
10

20
6.0
4.0
2.5
1.5
1.0

10

6
5
4
3

1
0.1 0.2 0.3 0.4 0.6 0.8 1 2 3 4 5 6 8 10 20 30 40 50 60 80 100 200 300 500 1000
Current (u102A)
53
 Selection and application
3 3-4 Wiring protection

3-4-3 Application of protective devices (2) Wiring protection by MCCBs

(1) Principle The MCCB to be used for overcurrent protection of wiring
When an overcurrent fault occurs, a circuit breaker must be can be selected by observing the principle in item (1). In
chosen that can interrupt an overcurrent before the wire is the short- time region discussions, remember that the
heated above its allowable temperature. The rated current tripping characteristic curve of an MCCB may cross the
of the circuit breaker thus must be lower than the allowable allowable current characteristic curve of wire near the point of
current of the wire. In the short-time region, the circuit breaker intersection of the inverse time-delay trip and instantaneous
should exhibit operating characteristics below the allowable trip characteristics of the MCCB.
current-time characteristics of the wire as shown in Fig. 3-13. Table 3-10 shows the combinations of MCCBs and PVC wires
In the short-circuit region it is necessary to verify, by way of available for protection in the short-time region. Protection
calculation, that the max. breaking I2t value of the overcurrent for wires in the short-circuit region can be determined by
protective device is lower than the allowable I2t value of the reviewing
wire. the allowable I2t value of the wire. Table 3-11 shows the max.
breaking I2t values of MCCBs at the time of short-circuit
current breaking and the allowable I2t values of wires needed
Fig. 3-13 Protection coordination for wiring to accomplish this determination.

Wire's allowable characteristics

(Short-time region)
Time

I2t = Constant
(short-circuit region)

MCCB operation characteristic

Current

Table 3-10 MCCB protected wiring (up to the rated short-time range)
Wire Allowable Allowable MCCB rating (A)
size current (A) current
(mm2) considering
Open Duct
MCCB trip
3-wire 3-wire
characteristics
(A)
Amb. temp. 30°C 30°Co100°C 10 15 20 40 50 60 75 100 125 150 175 200 225 250 300 350 400 500 600 700 800 1000
Rise 40K
1 14.5 10.2 12
1.5 18.5 13.0 18
2.5 25 18 27
4 34 24 40 Unprotected region
6 43 30 52
10 60 42 68
16 80 56 98
25 101 71 123
35 126 88 154 Protected region
50 153 107 187
70 196 137 239
95 238 167 290
120 276 193 337
150 319 223 389
185 364 255 444
240 430 301 525
300 556 389 678
400 664 465 810
500 757 530 924
630 856 599 967

54
 Selection and application
3-4 Wiring protection
3

Table 3-11a PVC wiring protected by rated breaking capacity (for short circuits)
Notes: 1 Wiring selection consideration: I2t of the wiring t maximum I2t of the MCCB (ELCB)
(Short-time wiring tempereture:160°C maximum, continuous region:70°C), and rated current of the wiring t rated current of the MCCB (ELCB).
2 The let-through current(I2t) is lower the MCCBs (ELCBs) in the table because short-circuit current can be limited by factors like wiring impedance in an actual
circuit. This lowers thermal stress on the wiring.

230V
MCCB (ELCB) PVC cable (Note: 1)
Icu Peak let- Max. let- Permissible I2t Minimum wire Permissible
(kA) through through (u10sA2s) size (mm2) current (A)
current current I2t
(kA: peak) (u10sA2s)
MCCB ELCB Rated current (A)
BW32AAG EW32AAG 3 (MCCB only), 5, 10, 15, 20, 30, 32 2.5 3.5 0.06 0.082 2.5 18
BW50AAG EW50AAG 5, 10, 15, 20, 30, 32, 40, 50 2.5 3.5 0.06 0.082 2.5 18
BW100AAG EW100AAG 60, 63, 75, 100 5.0 6.0 0.145 0.21 4 24
EW32EAG 5, 10, 15, 20, 30, 32 2.5 3.5 0.06 0.082 2.5 18
BW50EAG EW50EAG 5, 10, 15, 20, 30, 32, 40, 50 5.0 6.0 0.145 0.21 4 24
BW63EAG EW63EAG 60, 63 5.0 6.0 0.145 0.21 4 24
BW100EAG EW100EAG 50, 60, 63, 75, 100 25 12.0 0.50 1.31 10 42
BW160EAG EW160EAG 125, 150, 160 36 25.0 1.70 3.35 16 56
BW250EAG EW250EAG 175, 200, 225, 250 36 25.0 1.70 3.35 16 56
BW400EAG EW400EAG 250, 300, 350, 400 50 33.5 2.58 3.35 16 56
BW630EAG EW630EAG 500, 600, 630 50 47.0 5.10 8.2 25 71
BW800EAG EW800EAG 700, 800 50 47.0 5.10 8.2 25 71
BW125JAG EW125JAG 15 50 4.65 0.033 0.082 2.5 18
20 50 5.7 0.044 0.082 2.5 18
30 50 6.95 0.06 0.082 2.5 18
40, 50, 60, 75, 100, 125 50 20.0 0.62 1.31 10 42
BW160JAG EW160JAG 125, 150, 160 50 24.5 1.28 1.31 10 42
BW250JAG EW250JAG 175, 200, 225, 250 50 24.5 1.28 1.31 10 42
BW32SAG EW32SAG 3, 5, 10, 15, 20, 30, 32 5.0 6.0 0.145 0.21 4 24
BW50SAG EW50SAG 5, 10, 15, 20, 30, 32, 40, 50 10 8.5 0.27 0.471 6 30
BW63SAG EW63SAG 60, 63 10 8.5 0.27 0.471 6 30
BW125SAG EW125SAG 15 85 5.035 0.036 0.082 2.5 18
20 85 6.26 0.048 0.082 2.5 18
30 85 7.685 0.067 0.082 2.5 18
40, 50, 60, 75, 100, 125 85 23.5 0.746 1.31 10 42
BW160SAG EW160SAG 125, 150, 160 85 29.5 1.504 3.35 16 56
BW250SAG EW250SAG 175, 200, 225, 250 85 29.5 1.504 3.35 16 56
BW400SAG EW400SAG 250, 300, 350, 400 85 40.0 2.65 3.35 16 56
BW50RAG EW50RAG 10, 15, 20, 30, 32, 40, 50 25 12.0 0.50 1.31 10 42
BW63RAG EW63RAG 60, 63 25 12.0 0.50 1.31 10 42
BW125RAG EW125RAG 15 100 5.2 0.037 1.31 10 42
20 100 6.5 0.05 1.31 10 42
30 100 8.0 0.07 1.31 10 42
40, 50, 60, 75, 100, 125 100 25.0 0.08 1.31 10 42
BW160RAG EW160RAG 125, 150, 160 100 31.5 1.60 3.35 16 56
BW250RAG EW250RAG 175, 200, 225, 250 100 31.5 1.60 3.35 16 56
BW400RAG EW400RAG 250, 300, 350, 400 100 42.0 3.02 3.35 16 56
BW630RAG EW630RAG 500, 600, 630 100 61.5 6.50 8.18 25 71
BW800RAG EW800RAG 700, 800 100 61.5 6.50 8.18 25 71
BW50HAG 15 125 5.40 0.039 0.082 2.5 18
20 125 6.8 0.051 0.082 2.5 18
30 125 8.3 0.07 0.082 2.5 18
40, 50 125 26.5 0.85 1.31 10 42
BW125HAG 15 125 5.40 0.039 0.082 2.5 18
20 125 6.8 0.051 0.082 2.5 18
30 125 8.3 0.07 0.082 2.5 18
40, 50, 60, 75, 100, 125 125 26.5 0.85 1.31 10 42
BW250HAG 125, 150, 160, 175, 200, 225, 250 125 33.3 1.68 3.35 16 56
BW400HAG EW400HAG 250, 300, 350, 400 125 45.0 3.10 3.35 16 56
BW630HAG EW630HAG 500, 600, 630 125 66.5 6.8465 8.18 25 71
BW800HAG EW800HAG 700, 800 125 66.5 6.8465 8.18 25 71

55
 Selection and application
3 3-4 Wiring protection

Table 3-11b PVC wiring protected by rated breaking capacity (for short circuits)
Notes: 1 Wiring selection consideration: I2t of the wiring t maximum I2t of the MCCB (ELCB)
(Short-time wiring tempereture:160°C maximum, continuous region:70°C), and rated current of the wiring t rated current of the MCCB (ELCB).
2 The let-through current(I2t) is lower the MCCBs (ELCBs) in the table because short-circuit current can be limited by factors like wiring impedance in an actual
circuit. This lowers thermal stress on the wiring.

440V
MCCB (ELCB) PVC cable (Note: 1)
Icu Peak let- Max. let- Permissible I2t Minimum wire Permissible
(kA) through through (u10sA2s) size (mm2) current (A)
current current I2t
(kA: peak) (u10sA2s)
MCCB ELCB Rated current (A)
BW32AAG 3, 5, 10, 15, 20, 30, 32 1.5 2.1 0.03 0.082 2.5 18
BW50AAG 5, 10, 15, 20, 30, 32, 40, 50 1.5 2.1 0.03 0.082 2.5 18
BW100AAG 60, 63, 75, 100 1.5 2.1 0.03 0.082 2.5 18
BW50EAG EW50EAG 5, 10, 15, 20, 30, 32, 40, 50 2.5 3.5 0.08 0.082 2.5 18
BW63EAG EW63EAG 60, 63 2.5 3.5 0.08 0.082 2.5 18
BW100EAG EW100EAG 50, 60, 63, 75, 100 10 10.0 0.60 1.31 10 42
BW160EAG EW160EAG 125, 150, 160 18 22.0 2.60 3.35 16 56
BW250EAG EW250EAG 175, 200, 225, 250 18 22.0 2.60 3.35 16 56
BW400EAG EW400EAG 250, 300, 350, 400 30 35.0 5.70 8.18 25 71
BW630EAG EW630EAG 500, 600, 630 36 47.0 8.75 16.0 35 88
BW800EAG EW800EAG 700, 800 36 47.0 8.75 16.0 35 88
BW125JAG EW125JAG 15 30 8.1 0.113 0.21 4 24
20 30 9.5 0.140 0.21 4 24
30 30 11.0 0.178 0.21 4 24
40, 50, 60, 75, 100, 125 30 10.0 1.65 3.35 16 56
BW160JAG EW160JAG 125, 150, 160 30 26.0 3.15 3.35 16 56
BW250JAG EW250JAG 175, 200, 225, 250 30 26.0 3.15 3.35 16 56
BW32SAG EW32SAG 3, 5, 10, 15, 20, 30, 32 2.5 3.5 0.08 0.082 2.5 18
BW50SAG EW50SAG 5, 10, 15, 20, 30, 32, 40, 50 7.5 8.3 0.41 0.471 6 30
BW63SAG EW63SAG 60, 63 7.5 8.3 0.41 0.471 6 30
BW125SAG EW125SAG 15 36 8.2 0.115 0.21 4 24
20 36 9.65 0.145 0.21 4 24
30 36 11.3 0.183 0.21 4 24
40, 50, 60, 75, 100, 125 36 21.5 1.815 3.35 16 56
BW160SAG EW160SAG 125, 150, 160 36 28.1 3.45 8.18 25 71
BW250SAG EW250SAG 175, 200, 225, 250 36 28.1 3.45 8.18 25 71
BW400SAG EW400SAG 250, 300, 350, 400 36 38.0 6.40 8.18 25 71
BW50RAG EW50RAG 10, 15, 20, 30, 32, 40, 50 10 10.0 0.60 1.31 10 42
BW63RAG EW63RAG 60, 63 10 10.0 0.60 1.31 10 42
BW125RAG EW125RAG 15 50 8.5 0.120 1.31 10 42
20 50 10.0 0.155 3.35 16 56
30 50 12.0 0.195 3.35 16 56
40, 50, 60, 75, 100, 125 50 25.0 2.20 3.35 16 56
BW160RAG EW160RAG 125, 150, 160 50 33.0 4.15 8.18 25 71
BW250RAG EW250RAG 175, 200, 225, 250 50 33.0 4.15 8.18 25 71
BW400RAG EW400RAG 250, 300, 350, 400 50 44.0 7.70 8.18 25 71
BW630RAG EW630RAG 500, 600, 630 50 54.5 10.30 16 35 88
BW800RAG EW800RAG 700, 800 50 54.5 10.30 16 35 88
BW50HAG 15 65 8.55 0.121 0.21 4 24
20 65 10.5 0.160 0.21 4 24
30 65 12.6 0.20 0.21 4 24
40, 50 65 27.3 2.40 3.35 16 56
BW125HAG 15 65 8.55 0.121 0.21 4 24
20 65 10.5 0.160 0.21 4 24
30 65 12.6 0.20 0.21 4 24
40, 50, 60, 75, 100, 125 65 27.3 2.40 3.35 16 56
BW250HAG 125, 150, 160, 175, 200, 225, 250 65 36.2 4.50 8.18 25 71
BW400HAG EW400HAG 250, 300, 350, 400 70 50.0 8.70 16 35 88
BW630HAG EW630HAG 500, 600, 630 70 63.5 11.97 16 35 88
BW800HAG EW800HAG 700, 800 70 63.5 11.97 16 35 88

56
 Selection and application
3-5 Motor circuit applications
3

3-5 Motor circuit applications secs. Pump motors require a shorter starting time, while fans
and blowers require a longer time to reach operating speed.
3-5-1 Description
Fig. 3-14 Starting power factor example of induction motors
Individual or tandem overcurrent protective devices are
80
installed in motor circuits to provide the motor with overload 70
and locked rotor protection and to provide the wiring with

Starting power factor (%)

60
overcurrent protection. These protective devices must operate 50
at or below current-time characteristics for the motor windings 40
to reach the allowable temperature. Any of the combinations
in Fig. 3-16 would provide adequate protection for actual 30
motor circuits depending on the motor capacity, operating
characteristics, frequency of operation, switching durability and 20
short-circuit capacity.
(a) Motor protection MCCB only
(b) Motor protection MCCB plus magnetic contactor
10
(c) Magnetic motor starter plus line protection MCCB 0.5 1 2 3 4 5 10 20 30 40 50 100 200 300 500

(d) Magnetic motor starter plus instantaneous trip type MCCB Motor output (kW)
The MCCBs in (a) and (b) provide both overcurrent and short-
circuit protection. With configurations (c) and (d), the motor
starter provides overload protection while a line protection or Fig. 3-15 DC component overlap ratio
instantaneous trip type MCCB provides short-circuit protection.
3.0 2.0
Combination (d) acts as a single overcurrent circuit breaker for
: Max. asymmetrical instantaneous coefficient
one panel. : Max. asymmetrical effective value coefficient

(1) Motor starting current

2.0 1.5
Unlike the situation with loads like lamps, starting current and
inrush current exceeding the full load current flow when motor
circuits start up. Therefore, motor circuits need overcurrent
protection devices that will not be tripped by these starting
currents. 1.0 1.0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
(a) Direct-on-line starters (Full voltage starting)
Circuit power factor (cos )
These are some of the problems to be solved when starting a
squirrel-cage induction motor directly-on-line.
1) An asymmetrical current flows at the time the motor starts (b) Star-delta starters
due to the symmetrical AC component and DC components. Although it takes little time to changeover from star to delta
This causes the instantaneous trip mechanism to operate. connection, the inrush current at this time is significant. This
2) The inverse time-delay trip mechanism will operate due to inrush current occurs when voltage higher than the power
the longer starting time. 1
supply voltage (1 + | 1.58 times in the worst case
The magnitude of the starting currents (symmetrical AC —3
component) varies according to the type of motor, outputs,
and the number of poles. However, overcurrents generally scenario) is applied to the motor because of residual voltage
equal to 500% to 800% of the full load current will flow. For generated in the motor stator winding and by the phase
FUJI standard motors, approximately a 600% overload can be differential with the power supply voltage when a delta
expected. connection is performed.
A few cycles immediately after starting the DC component will The amount of inrush current in the worst case scenario is 1.1
overlap. to 1.3 times the starting current u 1.58, which is direct-on-line
The magnitude of the asymmetrical current can be obtained starting. If the starting current momentarily reaches 800% of
from the relations given in Fig. 3-14 and 3-15. the full load current, then the inrush current in the worst case
These two diagrams are used as follows. For instance, for a scenario is 800% of the full load current u 1.3 u 1.58 | 1700%.
55kW induction motor, the starting power factor cosM will be The instantaneous trip device in the MCCB may trip if its
0.22. The effective value of D, including the DC component, is setting is exceeded for even a 1/2 cycle, so an MCCB must be
1.23. Therefore, the asymmetrical currents can be expressed selected where the instantaneous trip current is higher than
as follows. the inrush current described above.
Symmetrical starting current u 1.23 (effective value). In this
example, assuming that the starting current’s multiplication
factor is 600%, the asymmetrical currents are approx. 750%. If
the factor is 800% the latter is approx. 1000%.
The MCCB’s instantaneous trip value will have to exceed this
value. The starting period of a motor depends on the GD2 of
the load. Strictly speaking, this must be calculated for each
motor. However, the starting period is generally less than 10

57
 Selection and application
3 3-5 Motor circuit applications

(2) Motor circuit protection by motor breaker Fig. 3-16 Motor breaker protection coordination
The overcurrent trip characteristics of a single MCCB may Motor breaker characteristics
be used to protect the motor and the wiring at the same time. Cable allowable characteristics
(See Fig. 3-17 a.)
Often the operating characteristics of an MCCB make it Motor allowable characteristics
unsuitable in situations with long starting times or with

Time
significant current, like the inrush current generated by the
changeover from star to delta connection. However, MCCBs
are quite suitable for short (2s or less) starting times. Motor current
The need for frequent switching brings up other important
considerations, such as connecting magnetic contractors in
series. (See Fig. 3-17 b.) Fig. 3-16 shows the MCCB protection Current
coordination curve. Table 3-12 (a) shows applicable breakers
for 230V motors and Table 3-12 (b) shows breakers for 400V
motors.

Fig. 3-17 Protective structure for motor circuits

Motor protection Motor protection

MMS MCCB or MMS Instantaneous trip type MCCB
Line protection
MCCB

Contactor Starter Starter

M M M M

a b c d

Table 3-12 Selection of manual motor starters (MMS)

(a) 230V AC
Combined Motor output Motor rated Motor rated Manual motor Manual motor starter
magnetic (kW) current (A) current starter rated Icu (kA)
contactor multiplying current (A) 50 100
factor (A)u1.2
SC-03 0.2 0.96 1.15 1.2 – BM3RSB-†
0.4 1.65 1.98 2.3 BM3RHB-†
0.75 2.87 3.45 3.5 BM3VSB-†
1.5 5.2 6.3 7 BM3VHB-†
2.2 7.0 8.4 9
SC-4-0 3.7 11.7 14.1 14 BM3RSB-†
SC-N1 5.5 17.4 20.9 21 BM3VSB-† BM3RHB-†
SC-N2 7.5 23.1 27.7 28 BM3VSB-† BM3VHB-†
SC-N2S 11 33.9 40.7 40 BM3VHB-†
SC-N3 15 45.2 54.3 52
SC-N4 18.5 54.8 65.8 65 – –
SC-N5, N5A 22 67 80.4 80
SC-N6 30 89.6 107.5 110 – –
SC-N7 37 110.5 132.6 130
SC-N8 45 132.2 158.7 150
SC-N10 55 163.6 196.3 200

Note: Motor full-load currents are based on FUJI’s standard type totally-enclosed
induction motors. Check the value of the full-load current before using.

58
 Selection and application
3-5 Motor circuit applications
3

(a) 400V AC
Combined Motor output Motor rated Motor rated Manual motor Manual motor starter
magnetic (kW) current (A) current starter rated Icu (kA)
contactor multiplying current (A) 25 50 100
factor (A)u1.2
SC-03 0.2 0.55 0.66 0.7 – – BM3RSB-†
0.4 0.95 1.14 1.4 BM3RHB-†
0.75 1.65 1.98 2
1.5 3 3.6 4
2.2 4.05 4.86 5 BM3RSB-† BM3VSB-†
BM3VSB-† BM3VHB-†
SC-0, 05 3.7 6.75 8.1 8 BM3RSB-† BM3RHB-† –
SC-4-0 5.5 10 12 12 BM3VSB-† BM3VHB-†
SC-4-1, 5-1 7.5 13.25 15.9 16
SC-N1 11 19.5 23.4 24 BM3VSB-† BM3VHB-†
SC-N2 15 26 31.2 32
SC-N2S 18.5 31.5 37.8 40 – –
SC-N2S 22 38.5 46.2 45
SC-N3 30 51.5 61.8 60
SC-N4 37 63.5 76.2 75
SC-N5, N5A 45 76 91.2 90
SC-N6 55 94 112.8 125
SC-N7 75 128 153.6 150
SC-N8 90 152 182.4 175
SC-N10 110 185 222 225

Note: Motor full-load currents are based on FUJI’s standard type totally-enclosed
induction motors. Check the value of the full-load current before using.

59
 Selection and application
3 3-5 Motor circuit applications

(3) Magnetic motor starter and MCCB motor circuit Fig. 3-18 Protection coordination characteristics curve in motor
protection circuits

These arrangements consist of a magnetic motor starter TOR's operating characteristics 1

and line protection or instantaneous trip type of MCCB. The Motor allowable characteristics 2
starter’s thermal overload relay operates in the presence of MCCB's operating characteristics 3
sustained overload currents. The MCCB interrupts short-circuit
Cable allowable characteristics 4
currents. This is the most popular method.
For control centers where short-circuit currents are large,

Time
instantaneous trip type MCCBs are used. This is because Available
standard MCCBs for line protection are provided with bimetal short-circuit Rated short-
elements as tripping devices, which have limited overcurrent current circuit breaking
withstand values and which would cause damage due to capacity (Icu)
Motor current
overheating in the presence of short-circuit currents.
Fig. 3-18 gives an example of a protection coordination curve
of a motor circuit. Current

When combining the MCCB with a magnetic motor starter, the

Table 3-13 Magnetic motor starter protection class (IEC 60947-4-1)
fundamental rules for protection are as follows:
s 4HE COMBINED PROTECTION CHARACTERISTICS OF  AND  MUST Type 1 Coordination requires that, under short-circuit conditions,
the contactor or starter shall cause no danger to persons
operate before the motor and wire sustain damage.
or installation and may not be suitable for further service
s 4HE -##" DOES NOT TRIP FROM STARTING CURRENT OR FROM without repair and replacement of parts.
current while the motor is running at the rated load.
s 4HE -##" MUST BE ABLE TO INTERRUPT SHORT CIRCUIT CURRENTS Type 2 Coordination requires that, under short-circuit conditions,
s )N AN OVERLOAD CONDITION THE STARTER OPERATES BEFORE THE the contactor or starter shall cause no danger to persons
MCCB. or installation and shall be suitable for further use. The
risk of contact welding is recognized, in which case the
s 4HE -##" OPERATES WHEN MORE CURRENT mOWS THAN THE
manufacturer shall indicate the measures to be taken as
starter can interrupt. This protects the starter. regards the maintenance of the equipment.
Even though the above requirements are satisfied and the
MCCB interrupts, the heating element of the thermal overload
relay can be damaged due to overheating caused by the
magnetic force or the energy of the short-circuit currents.
This means that it is impossible for the MCCB to provide
absolute protection for motor starters when short-circuit faults
occur. It is therefore not realistic or economical to protect
magnetic motor starters by means of MCCBs.
Therefore, magnetic motor starter protection is divided into two
types by IEC 60947-4-1, with the prior understanding that the
motor starter must be replaced or repaired after a short-circuit
fault has occurred. Refer to Table 3-13.

60
 Selection and application
3-5 Motor circuit applications
3

Table 3-14 Selection of line protection MCCB and ELCB (for reference)
(a) 230V AC 3-phase induction motor
Contactor Thermal Motor ratings MCCB Icu (kA)
type overload Current Output rated 2.5 5 10 25 36 50 85 100 125
relay type (A) (kW) current
(A)
SC-03 TR-0N/3 1.3 0.2 5 BW32AAG BW32SAG BW50SAG
2.3 0.4 5 BW32AAG BW32SAG BW50SAG
3.5 0.75 10 BW32AAG BW32SAG BW50SAG BW50RAG
15 BW125JAG BW125SAG BW125RAG BW50HAG
6.9 1.5 20 BW32AAG BW32SAG BW50SAG BW50RAG BW125JAG BW125SAG BW125RAG BW50HAG
9.5 2.2 30 BW32AAG BW32SAG BW50SAG BW50RAG BW125JAG BW125SAG BW125RAG BW50HAG
SC-4-0 TR-5-1N/3 15.5 3.7 40 BW50AAG BW50EAG BW50SAG BW50RAG BW125JAG BW125SAG BW125RAG BW50HAG
SC-N1 TR-N2/3 21 5.5 50 BW50AAG BW50EAG BW50SAG BW50RAG BW125JAG BW125SAG BW125RAG BW50HAG
SC-N2 27.5 7.5 60 BW125JAG BW125SAG BW125RAG BW50HAG
75 BW100AAG BW100EAG
SC-N2S TR-N3/3 40 11 100 BW125JAG BW125SAG BW125RAG BW50HAG
SC-N3 54 15 100 BW125JAG BW125SAG BW125RAG BW50HAG
SC-N4 TR-N5/3 68 18.5 125 BW125JAG BW125SAG BW125RAG BW50HAG
SC-N5 84 22 125 BW160EAG BW160JAG BW160SAG BW160RAG BW250HAG
SC-N5A
SC-N6 TR-N6/3 116 30 175 BW250EAG BW250JAG BW250SAG BW250RAG BW250HAG
SC-N7 TR-N7/3 137 37 225 BW250EAG BW250JAG BW250SAG BW250RAG BW250HAG
SC-N8 TR-N8/3 166 45 250 BW250EAG BW250JAG BW250SAG BW250RAG BW250HAG
SC-N10 TR-N10/3 200 55 350 BW400EAG BW400SAG BW400RAG BW400HAG
SC-N11 TR-N12/3 272 75 500 BW630EAG BW630RAG BW630HAG
SC-N12 332 90 500 BW630EAG BW630RAG BW630HAG
380 110 500 BW630EAG BW630RAG BW630HAG

Notes 1 : The model numbers to use for direct-on-line starters are given for electromagnetic contractors.
2 : The model numbers for AC3-class electromagnetic contactors are given.
3 : The catalog values are given for the rated motor current (catalog number 24B2-E-0087) for Fuji 3-phase totally enclosed fan-cooled models (4-pole,
200V/50Hz with feet).

61
 Selection and application
3 3-5 Motor circuit applications

Table 3-14 Selection of line protection MCCB and ELCB (for reference)
(b) 400V AC 3-phase induction motor
Contactor Thermal Motor ratings MCCB Icu (kA)
type overload Current Output rated 2.5 7.5 10 18 30 36 50 68 70
relay type (A) (kW) current
(A)
SC-03 TR-0N/3 0.65 0.2 5 BW32SAG BW50SAG
1.15 0.4 5 BW32SAG BW50SAG
1.8 0.75 5 BW32SAG BW50SAG
3.5 1.5 10 BW32SAG BW50SAG BW50RAG
4.8 2.2 15 BW32SAG BW50SAG BW50RAG BW125JAG BW125SAG BW125RAG BW50HAG
SC-0 TR-0N/3 7.8 3.7 20 BW32SAG BW50SAG BW50RAG BW125JAG BW125SAG BW125RAG BW50HAG
SC-05
SC-4-0 TR-5-1N/3 10.5 5.5 30 BW32SAG BW50SAG BW50RAG BW125JAG BW125SAG BW125RAG BW50HAG
SC-4-1 TR-5-1N/3 13.5 7.5 40 BW50EAG BW50SAG BW50RAG BW125JAG BW125SAG BW125RAG BW50HAG
SC-5-1
SC-N1 TR-N2/3 20 11 40 BW125JAG BW125SAG BW125RAG BW50HAG
60 BW63EAG BW63SAG BW63RAG
SC-N2 TR-N2/3 27 15 60 BW125JAG BW125SAG BW125RAG BW125HAG
75 BW100EAG
SC-N2S TR-N3/3 34 18.5 60 BW125JAG BW125SAG BW125RAG BW125HAG
100 BW100EAG
SC-N2S TR-N3/3 42 22 75 BW125JAG BW125SAG BW125RAG BW125HAG
100 BW100EAG
SC-N3 TR-N3/3 58 30 100 BW125JAG BW125SAG BW125RAG BW125HAG
SC-N4 TR-N5/3 69 37 125 BW125JAG BW125SAG BW125RAG BW125HAG
SC-N5 TR-N5/3 83 45 125 BW160JAG BW160SAG BW160RAG BW250HAG
SC-N5A
SC-N6 TR-N6/3 100 55 150 BW160JAG BW160SAG BW160RAG BW250HAG
SC-N7 TR-N7/3 136 75 200 BW250JAG BW250SAG BW250RAG BW250HAG
SC-N8 TR-N8/3 166 90 225 BW250JAG BW250SAG BW250RAG BW250HAG
SC-N10 TR-N10/3 190 110 300 BW400EAG BW400SAG BW400RAG BW400HAG
SC-N11 TR-N12/3 225 132 400 BW400EAG BW400SAG BW400RAG BW400HAG

Notes 1 : The model numbers to use for direct-on-line starters are given for electromagnetic contractors.
2 : The model numbers for AC3-class electromagnetic contactors are given.
3 : The catalog values are given for the rated motor current (catalog number 24B2-E-0087) for Fuji 3-phase totally enclosed fan-cooled models (4-pole,
400V/50Hz with feet).

62
 Selection and application
3-6 Applications on the primary side of transformers
3

3-6 Applications on the primary side of transformers

3-6-1 Inrush current for transformer excitation 3-6-2 Selecting an MCCB for transformer
The voltage V applied to the transformer in the normal primary circuit
condition is balanced by the voltage e induced by changes in The MCCB to be selected must be capable of carrying
the magnetic flux in the core. Only a slight exciting current is the rated current safely in the normal condition, without
needed to generate the flux flows through the primary winding. malfunctioning with the inrush current for exciting the
The following relationship exists between the induced voltage transformer.
e, the instantaneous value ø of the magnetic flux, and the More specifically, the MCCB is required to meet the following
primary winding n: relation:
e=n dø —2uIi > kulT1
dt
where
where e = EmsinZt yields ø = −ømcosZt + C. In a steady state Ii: MCCB instantaneous trip current (effective value)
(C = 0), the relationship is like that shown in Fig. 3-19. IT1: Transformer rated primary current (A) (peak value)
k: Transformer exciting inrush current multiplier
Fig. 3-19 Relationship of induction voltage to magnetic flux in a
steady-state transformer
This relation is illustrated in Fig. 3-21.

e Fig. 3-21 Relationship of induction voltage to magnetic flux in a

ø
steady-state transformer

0 IN
øm

T IT1
t=0
Time

Accordingly, assuming that excitation of the transformer

is started at t=0, the magnetic flux ø must be 0 if the prior Transformer MCCB operating
residual flux is 0. The flux exhibits ø as shown in Fig. exciting inrush characteristic
3-20, which is far above the core saturation flux øs of the current
transformer. However, as the magnetic flux ø is saturated to
the value of øs for the period from t1 to t2, the induced voltage
e=n dø
dt is no longer balanced with the voltage V applied to the
transformer, when a difference is created between the voltage IN Ii
Current
V applied to the transformer and induced voltage e. As a
result, inrush current i flows through the primary winding of the Transformer exciting inrush current and MCCB
transformer (Fig. 3-20). operating characteristic
To select an MCCB for line protection, if the instantaneous trip
Fig. 3-20 Transformer excitation inrush current current (Ii) is eight times the rated MCCB current (In), and the
transformer exciting inrush current multiplier (k) is 20 (typical
i value for 100kVA class transformers), the following relation
holds:
ø —2u8uIn > 20ulT1
øs This suggests that an MCCB with its rated current at least 1.8
2øm times higher than the transformer rated primary current must
be selected.
0 MCCBs designed for transformer primary circuits have their
t1 t2 operating characteristics set up to meet the above conditions,
t=0 and feature a rated current lower than that of an MCCB for line
protection. Table 3-15 and 3-16 show single-phase transformer
When the transformer core has residual magnetic flux, then applications while Fig. 3-17 and 3-18 show three-phase
the amount of inrush current and the amount of saturation will transformer applications.
increase by the amount of flux present. An MCCB is generally
made near voltage phase S/2 to prevent excitation inrush
current. With a three-phase transformer, however, it is done by
making the MCCB near voltage phase 0 at some phase.
The magnitude of the inrush current for excitation is generally
stated as an exciting inrush current multiplier (exciting inrush
current first peak value relative to the transformer rated
primary current peak value).
The exciting inrush current multiplier is a parameter of the
transformer ratings and design. Generally, the lower the
transformer capacity, the larger the exciting inrush current
multiplier and the shorter the time constant.

63
 Selection and application
3 3-6 Applications on the primary side of transformers

3-6-3 Transformer primary-side circuit selection inrush current if a voltage is applied

without a load and the power supply
Selection is performed based on the exciting inrush current of voltage is higher than the rated terminal
the 440V terminals for a primary rated voltage of 400V to 440V voltage at 50Hz.
(220V terminals for primary rated voltage of 200V to 220V)
and 50Hz for a 50Hz/60Hz transformer. Selection conditions: Exciting inrush current (Effective value
conversion = Rated current x Peak
Reason: The exciting inrush current decreases exciting inrush current factor) < MCCB
as the frequency rises. The current also instantaneous tripping current (effective
decreases as the voltage decreases. value at 0.01 s).
Therefore, the breaker may operate
incorrectly due to the large exciting

Table 3-15 Selecting MCCB for transformer primary circuit (Three-phase)

Three-phase, 400-440V/210V Transformers
Transformer capacity (kVA) 0.5 1.0 1.5 2.0 3.0 5.0 7.5 10
In: Rated primary current (rms A) 0.7 1.3 2 2.6 3.9 6.6 9.8 13.1
Irush: Exciting inrush current (rms A) 15.4 30.8 46.3 61.7 92.5 154.2 231.3 308.4
Short-circuit 1.5 (kA) BW32AAG–3P003 BW32AAG–3P005 BW32AAG–3P010 BW50SAT–3P015 BW32SAT–3P020
current at 440V
2.5 (kA) BW32SAG–3P003 BW32SAG–3P005 BW32SAG–3P010 BW50SAT–3P015 BW32SAT–3P020
7.5 (kA) BW50SAG–3P005 BW50SAG–3P010 BW50SAT–3P015 BW50SAT–3P020
10 (kA) BW50RAG–3P010 BW50RAG–3P020 BW50RAG–3P040
18 (kA) BW125JAG–3P015
30 (kA) BW125JAG–3P015
36 (kA) BW125RAG–3P015
50 (kA) BW125RAG–3P015
65 (kA) BW50HAG-3P015

Transformer capacity (kVA)

In: Rated primary current (rms A)
Irush: Exciting inrush current (rms A)
Short-circuit 1.5 (kA)
current at 440V
2.5 (kA)
7.5 (kA)
10 (kA)
18 (kA)
30 (kA)
36 (kA)
50 (kA)
65 (kA)
Note: Peak inrush current used in calculations: 20kVA max.: 23.5 times the rated

Three-phase, 200-220V/105V Transformers

Transformer capacity (kVA) 0.5 1.0 1.5 2.0 3.0 5.0 7.5 10
In: Rated primary current (rms A) 1.312 2.624 3.936 5.249 7.873 13.122 19.682 26.243
Irush: Exciting inrush current (rms A) 30.836 61.672 92.507 123.343 185.015 308.358 462.536 616.715
Short-circuit 2.5 (kA) BW32AAG–3P005 BW32AAG–3P010 BW32AAG–3P015 BW32SAT–3P015 BW32SAT–3P020 BW32SAT–3P030 BW50SAT–3P040
current at 220V
5 (kA) BW32SAG–3P005 BW32SAG–3P010 BW32SAG–3P015 BW32SAT–3P015 BW32SAT–3P020 BW32SAT–3P030 BW32SAT–3P040
10 (kA) BW50SAG–3P010 BW50SAG–3P015 BW50SAT–3P015 BW50SAT–3P020 BW50SAT–3P030 BW50SAT–3P040
25 (kA) BW50RAG–3P010 BW50RAG–3P015 BW50RAG–3P020 BW50RAG–3P040 BW50RAG–3P050 BW100EAG–3P060
36 (kA) BW125JAG–3P015 BW125JAG–3P060 BW125JAT–3P060
50 (kA) BW125JAG–3P015 BW125JAG–3P060 BW125JAT–3P060
85 (kA) BW125RAG–3P015 BW125RAG–3P060 BW125RAG–3P100
100 (kA) BW125RAG–3P015 BW125RAG–3P060 BW125RAG–3P100
125 (kA) BW50HAG-3P015 BW125HAG–3P060 BW125HAG–3P100

Transformer capacity (kVA) 15 20 30 50 75 100 150 200

In: Rated primary current (rms A) 39.365 52.486 78.730 131.216 196.824 262.432 393.648 524.864
Irush: Exciting inrush current (rms A) 925.073 1233.430 1417.132 2361.887 3542.831 4723.775 7085.662 9447.550
Short-circuit 2.5 (kA) BW50SAT–3P050 BW100EAT–3P075 BW100EAT–3P100 BW250EAT–3P150 BW400EAT–3P250 BW400EAT–3P300 − −
current at 220V
5 (kA) BW50SAT–3P050 BW100EAT–3P075 BW100EAT–3P100 BW250EAT–3P150 BW400EAT–3P250 BW400EAT–3P300 − −
10 (kA) BW50SAT–3P050 BW100EAT–3P075 BW100EAT–3P100 BW250EAT–3P150 BW400EAT–3P250 BW400EAT–3P300 − −
25 (kA) BW100EAT–3P060 BW100EAT–3P075 BW100EAT–3P100 BW250EAT–3P150 BW400EAT–3P250 BW400EAT–3P300 − −
36 (kA) BW125JAT–3P060 BW125JAT–3P075 BW125JAT–3P090 BW250EAT–3P150 BW400EAT–3P250 BW400EAT–3P300 − −
50 (kA) BW125JAT–3P060 BW125JAT–3P075 BW125JAT–3P090 BW250RAT–3P150 BW400EAT–3P250 BW400EAT–3P300 − −
85 (kA) BW250RAG–3P125 BW250RAT–3P125 BW250RAT–3P150 BW400RAT–3P250 BW400RAT–3P300 − −
100 (kA) BW250RAG–3P125 BW250RAT–3P125 BW250RAT–3P150 BW400RAT–3P250 BW400RAT–3P300 − −
125 (kA) BW250HAG–3P125 BW250HAG–3P175 BW400HAG–3P250 BW400HAG–3P300 BW630HAG–3P500 BW630HAG–3P600 − −
Note: Peak inrush current used in calculations: 20kVA max.: 23.5 times the rated

64
 Selection and application
3-6 Applications on the primary side of transformers
3

Table 3-15 Selecting MCCB for transformer primary circuit (Single-phase)

Single-phase, 400-440V/210-105V Transformers
Transformer capacity (kVA) 0.5 1.0 1.5 2.0 3.0 5.0
In: Rated primary current (rms A) 1.1 2.3 3.4 4.5 6.8 11.4
Irush: Exciting inrush current (rms A) 28.4 56.8 85.2 113.6 170.5 284.1
Short-circuit 1.5 (kA) BW32AAG–2P003 BW32AAG–2P010 BW32AAG–2P015 BW32SAT–2P015
current at 440V
2.5 (kA) BW32SAG–2P003 BW32RAG–2P010 BW32SAG–2P015 BW32SAT–2P015
7.5 (kA) BW50SAG–2P010 BW50SAG–2P015 BW50SAT–2P015
10 (kA) BW50RAG–2P015 BW50RAG–2P020 BW50RAG–2P030
18 (kA) BW125JAG–2P015
30 (kA) BW125JAG–2P015
36 (kA) BW125RAG–2P015
50 (kA) BW125RAG–2P015
65 (kA) BW50HAG-2P015

Transformer capacity (kVA) 7.5 10 15 20 30 50 75 100

In: Rated primary current (rms A) 17.0 22.7 34.1 45.5 68.2 113.6 170.5 227.3
Irush: Exciting inrush current (rms A) 426.1 568.2 852.3 1136.4 1704.5 2840.9 4261.4 5681.8
Short-circuit 1.5 (kA) BW32SAT–2P030 BW50SAT–2P045 BW125JAT–2P060 BW125JAT–2P090 BW250EAT–2P175 BW400EAT–2P300 BW400EAT–2P400
current at 440V
2.5 (kA) BW32SAT–2P030 BW50SAT–2P045 BW125JAT–2P060 BW125JAT–2P090 BW250EAT–2P175 BW400EAT–2P300 BW400EAT–2P400
7.5 (kA) BW50SAT–2P030 BW50SAT–2P045 BW125JAT–2P060 BW125JAT–2P090 BW250EAT–2P175 BW400EAT–2P300 BW400EAT–2P400
10 (kA) BW50RAG–2P040 BW63RAG–2P060 BW125JAT–2P060 BW125JAT–2P090 BW250EAT–2P175 BW400EAT–2P300 BW400EAT–2P400
18 (kA) BW125JAG–2P060 BW125JAT–2P060 BW125JAT–2P090 BW250EAT–2P175 BW400EAT–2P300 BW400EAT–2P400
30 (kA) BW125JAG–2P060 BW125JAT–2P060 BW125JAT–2P090 BW250RAT–2P175 BW400EAT–2P300 BW400EAT–2P400
36 (kA) BW125RAG–2P060 BW125RAG–2P075 BW125RAG–2P125 BW250RAT–2P125 BW250RAT–2P175 BW400RAT–2P300 BW400RAT–2P400
50 (kA) BW125RAG–2P060 BW125RAG–2P075 BW125RAG–2P125 BW250RAT–2P125 BW250RAT–2P175 BW400RAT–2P300 BW400RAT–2P400
65 (kA) BW125HAG–3P060 BW125HAG–2P075 BW125HAG–2P125 BW250HAG–2P150 BW400HAG–2P250 BW400HAG–2P400 − −
Note: A peak inrush current of 25 times the rated current is used in the calculations.

Single-phase, 200-220V/100-115V Transformers

Transformer capacity (kVA) 0.5 1.0 1.5 2.0 3.0 5.0
In: Rated primary current (rms A) 2.3 4.5 6.8 9.1 13.6 22.7
Irush: Exciting inrush current (rms A) 56.8 113.6 170.5 227.3 340.9 568.2
Short-circuit 2.5 (kA) BW32AAG-2P010 BW32AAG-2P015 BW32SAT-2P015 BW32SAT-2P020 BW32SAT-2P030
current at 220V
5 (kA) BW32SAG-2P010 BW32SAG-2P015 BW32SAT-2P015 BW32SAT-2P020 BW32SAT-2P030
10 (kA) BW50SAG-2P010 BW50SAG-2P015 BW50SAT-2P015 BW50SAT-2P020 BW50SAT-2P030
25 (kA) BW50RAG-2P010 BW50RAG-2P015 BW50RAG-2P020 BW50RAG-2P030 BW50RAG-2P040 BW63RAG-2P060
36 (kA) BW125JAG-2P015 BW125JAG-2P075
50 (kA) BW125JAG-2P015 BW125JAG-2P075
85 (kA) BW125RAG-2P015 BW125RAG-2P075
100 (kA) BW125RAG-2P015 BW125RAG-2P075
125 (kA) BW50HAG-2P015 BW50HAG-2P075

Transformer capacity (kVA) 7.5 10 15 20 30 50 75 100

In: Rated primary current (rms A) 34.1 45.5 68.2 90.9 136.4 227.3 340.9 454.5
Irush: Exciting inrush current (rms A) 852.3 1136.4 1704.5 2272.7 3409.1 5681.8 8522.7 11363.6
Short-circuit 2.5 (kA) BW50EAT-2P045 BW100EAT-2P075 BW125JAT-2P100 BW250EAT-2P150 BW250EAT-2P200 BW400EAT-2P400 BW630RAT-3P600 −
current at 220V
5 (kA) BW50EAT-2P045 BW100EAT-2P075 BW125JAT-2P100 BW250EAT-2P150 BW250EAT-2P200 BW400EAT-2P400 BW630RAT-3P600 −
10 (kA) BW50SAT-2P045 BW100EAT-2P075 BW125JAT-2P100 BW250EAT-2P150 BW250EAT-2P200 BW400EAT-2P400 BW630RAT-3P600 −
25 (kA) BW100EAG-2P100 BW100EAT-2P075 BW125JAT-2P100 BW250EAT-2P150 BW250EAT-2P200 BW400EAT-2P400 BW630RAT-3P600 −
36 (kA) BW125JAT-2P060 BW125JAT-2P075 BW125JAT-2P100 BW250EAT-2P150 BW250EAT-2P200 BW400EAT-2P400 BW630RAT-3P600 −
50 (kA) BW125JAT-2P060 BW125JAT-2P075 BW125JAT-2P100 BW250RAT-2P150 BW250RAT-2P200 BW400EAT-2P400 BW630RAT-3P600 −
85 (kA) BW125RAG-2P125 BW250RAG-2P150 BW250RAG-2P225 BW250RAT-2P150 BW250RAT-2P200 BW400RAT-2P400 BW630RAT-3P600 −
100 (kA) BW125RAG-2P125 BW250RAG-2P150 BW250RAG-2P225 BW250RAT-2P150 BW250RAT-2P200 BW400RAT-2P400 BW630RAT-3P600 −
125 (kA) BW125HAG-2P125 BW250HAG-2P150 BW250HAG-2P225 BW400HAG-2P300 BW630HAG-3P500 − − −
Note: A peak inrush current of 25 times the rated current is used in the calculations.

65
 Selection and application
3 3-7 Welder circuit applications

3-7 Welder circuit applications Fig. 3-22 Typical intermittent operation

tL
3-7-1 Arc welders
MCCBs installed in arc welder circuits should not inadvertently
IL
trip due to the massive inrush current generated at ignition.
Inadvertent tripping often occurs when inrush current instantly t
trips the overcurrent tripping element in the MCCB. Since
TL
the transient inrush current in arc welders is 8 to 9 times the
primary current, an MCCB that can handle at least ten times T
the rated primary current without tripping should be selected
for this kind of application. (b) Transient inrush current caused by switching
transformer primary circuit
3-7-2 Resistance welders For resistance welders load switching is carried out in the
(1) Characteristics specific to resistance welder primary circuit of the welder transformer. Consequently, a high
circuits transient inrush current may flow when the circuit is closed, as
Resistance welders are characterized by intermittent operation mentioned under “Selecting an MCCB for transformer primary
with short switching intervals and also by switching in the circuit” (See page 63).
primary circuit of the welder transformer. Consequently, the Whether or not inrush current flows depends on the type of
following points must be considered when selecting an MCCB: switching control system used in resistance welders because
inrush current is generated by the closed circuit phase or
(a) Thermal equivalent current by residual magnetic flux in the transformer core. Switching
is controlled using synchronous, semi-synchronous, or
The current that flows through the welding circuit is repetitive asynchronous systems.
with short periods as shown in Fig. 3-22. Since the MCCB Inrush current does not occur with synchronous control
operation or the temperature rise in the wire is determined systems because they can control the current flow start phase
by a thermal equivalent current, the current flowing during and they can reverse the start polarity by the time the current
intermittent operation must be converted to a thermally flow ends.
equivalent continuous current. Semi-synchronous control systems can control the current
(i) Thermal equivalent current Ia during period t (seconds) flow start phase, but cannot necessarily reverse the start
polarity by the time the current flow ends. Inrush current may
Assuming that the current flowing time for resistance welding therefore occur here due to biased excitation of the core, but
by the current IL [A] is tL (seconds) per point, and that this is generally not a problem because these systems can
resistance welding is conducted at one point per t (seconds), adequately control the making phase.
then the on-load factor D of the welder can be stated in an Most semi-synchronous control systems today use thyristors
equation as: for main current switching. With the anti-surge current
Current flowing time tL capability of the thyristor as well, these systems take the half
D= = cycle at the start of the closed circuit phase and insert it just
Period t
past the voltage phase S/2 to prevent inrush current.
In this current flowing state, the amount of heat W generated Asynchronous control systems use a magnetic contactor
by the total circuit resistance R per t (seconds) can be for main current switching. Here, the closed circuit phase
represented as generates massive inrush current as high as 20 times the
W = (IL)2·R·tL (joule) steady state current. This is why newer welders now use either
If this value is taken as the average amount of heat generated synchronous or semi-synchronous control systems.
per t (seconds), then the equation derives as follows.
W = (IL)2
r
Rr
tL
t t
= (IL)2r
Rr
D
= R(IL—D)2
This means that the generated heat is equal to the amount
of heat that would be generated upon continuous flow of the
current IL—D (A) . Hence, the thermal equivalent current Ia at
period t (seconds) can be stated as
Ia = IL—D (A)

(ii) Thermal equivalent current IB at period T (seconds)

In Fig. 3-22, the thermal equivalent current IB at period TL
(seconds) is similar to that at period t (seconds). At period T
(seconds), however, the thermal equivalent current IB can be
represented as:
IB = IL— E (A) where, E = nxtL/T
n = TL/t

66
 Selection and application
3-7 Welder circuit applications
3

(2) Selecting MCCBs (i) Reviewing the thermal equivalent current

(a) Basic rule With an on-load factor of 100%, the thermal equivalent current
can be stated in equation form as
Assuming that the welder is used in the operating condition

— 100 (A)
illustrated in Fig. 3-22, the MCCB to be used must meet the Rated capacity 50
following requirements: Thermal equivalent current= u
Rated voltage
(i) The rated current (IN) of the MCCB is higher than the
thermal equivalent current IB (IN > IB). Hence, the rated current of the MCCB must be at least equal
Allowing for possible supply voltage fluctuation, a margin of to this value.
some 10% would be recommended. (ii) Reviewing the method to prevent malfunctioning
(ii) The MCCB is not tripped by the primary input current. associated with the primary input current
The MCCB’s hot-start characteristic curves are positioned
above the points (tL, IL) and (TL, Ia) so that the currents IL The first step in reviewing the primary input current-time
and Ia (A) would not cause the MCCB to malfunction (Fig. characteristics of the resistance welder and the hot-start
3-23). characteristic of the MCCB is setting the operating time (tL)
(iii) The MCCB is free from malfunction due to inrush current associated with the allowable on-load factor (D) of the welder.
when the circuit is closed. Assuming that the intermittent loading cycle is 1 minute and
hence tL = 60·D/100 (seconds), the relationship between the
Fig. 3-23 Hot and cold MCCB operating characteristics operating time (tL) and the primary input current (IL) must be
represented.
Fig. 3-24 shows the relationship between the primary input
current and allowable operating time for a single-phase 200V
Cold resistance welder rated at 25kVA.
Hot
Since the equation

— On-load factor u Rated voltage

50 Rated capacity
TL Primary input current =

is derived from the relationship presented above, the

maximum operating limits of the welder can be calculated as
Time

follows:
125A for 50% on-load factor, (tL = 30 seconds)
280A for 10% on-load factor, (tL = 6 seconds)
884A for 1% on-load factor, (tL = 0.6 seconds)
tL
Fig. 3-24 Relationship between maximum primary input current
and operating time
IB IN Ia IL
Current
60
(b) Selecting MCCB based on welder ratings
30
If the operating conditions for the welder are not definite,
the MCCB to be used should be selected by allowing for the
maximum operating limits of the welder considering its ratings
Operating time tL (sec.)

or specifications.
6
The rated capacity of a resistance welder is indicated in
terms of a 50% on-load factor. Namely, the rated capacity
is defined as an input load that would meet the temperature
rise requirement when the welder is used with a 50% on-load
factor.
If the welder is to be used with a current different from that
0.6
available with a 50% on-load factor, it must be used with an
on-load factor that would cause an equivalent temperature rise
observed with a 50% on-load factor or lower.
The relationship between the primary input capacity and the 88.4 125 280 340 884
allowable on-load factor can be stated in an equation as
Primary input current IL (A)
2
Allowable on-load factor= Rated capacity u 50%
Primary input capacity
This equation may be used to examine all possible
combinations of the primary input capacity and the allowable
on-load factor.

67
 Selection and application
3 3-7 Welder circuit applications

However, since the standard maximum input is prescribed Table 3-19 Spot welder circuit motor breaker selection
for a resistance welder, even if the secondary circuit is fully Note: This table applies to models that can use a thyristor to perform phase
shorted, the maximum short-circuit current is some 30% control at startup for a synchronous or semi-synchronous system.
higher than the rated welding current (secondary current
Resistance welder Single-phase, 200V
corresponding to the standard maximum input) at most. Circuit short-circuit capacity (kA) (The
Consequently, allowance would be needed only for a value short-circuit current at the service entrance
about 30% higher than the current corresponding to the must be less than the following values.)
standard maximum input.
Assuming a standard maximum input of 55kVA at 230V AC Rated Maximu 5 25 36 50 100
capacity m input
single-phase, IL (max) is calculated as example example
(kVA) (kVA)
IL (max) = 55000 u 1.3 | 310 [A]
230 15 35 BW100 BW100 BW125JAG-
This result requires that the tL−IL curve shown in Fig. 3-24 AAG- EAG- 2P100
be positioned below the hot-start characteristic curve of the 2P100 2P100
MCCB in the range IL d 310 (A). A general guideline for filling 30 65 BW125JAG-2P125 BW125
this requirement is to set the rated current of the MCCB at RAG-
least 1.5 times higher than the thermal equivalent current 2P125
calculated in (i).
55 140 BW250EAG-2P225 BW250RAG-
(iii) Method to keep the MCCB free from malfunctioning 2P225
caused by the inrush current when the circuit is
closed.
Resistance welder Single-phase, 400V
With welders that use thyristors to permit closed circuit phase Circuit short-circuit capacity (kA)
control, such as those operating in synchronous or semi- (The short-circuit current at the
synchronous mode, the inrush current associated with the service entrance must be less
biased excitation of the transformer core would not be much than the following values.)
of a problem. Rather, only the inrush current associated with Rated Maximu 10 18 30 50
the superposed DC component needs to be considered. capacity m input
Specifically, a choice should be made of an MCCB having its example example
instantaneous tripping current at least two times the IL (max) (kVA) (kVA)
calculated in (ii).
15 35 BW50 BW125JAG- BW125
RAG- 2P050 RAG-
Table 3-19 lists typical MCCBs that are selected to work with 2P050 2P050
resistance welders that operate in synchronous or semi-
synchronous mode, pursuant to the requirements given in (i) 30 65 BW100 BW125JAG- BW125
to (iii) above. Since, generally, the standard maximum input EAG- 2P100 RAG-
2P100 2P100
of a welder is some three times its rated capacity, and the
instantaneous tripping current of an MCCB is eight times 55 140 BW250EAG-2P225 BW125
its rated current or higher, the following equation may be RAG-
used to select an MCCB to work with welders that operate in 2P125
synchronous or semi-synchronous mode:
Rated capacity
IN > 1.1 u IN = MCCB rated current
Rated voltage
Max. input capacity
Assumption: d3
Rated capacity

68
 Selection and application
3-8 Selecting an MCCB for capacitor circuit
3

3-8 Selecting an MCCB for capacitor circuit (2) Transient inrush current when a circuit closes
When a capacitor circuit like the one shown in Fig. 3-25
3-8-1 Characteristics specific to capacitor closes, the capacitor must be charged with an equivalent of
circuits the voltage applied the instant the circuit closed. This causes
Note the following points when considering MCCBs for the circuit to be flooded with massive inrush current that has a
capacitor circuits: steep slope like that shown in Fig. 3-27.
If the circuit closes now with peak supply voltage present, then
(1) Arc reignition due to recovery voltage the transient current at this time is expressed by the following
equation.
When a capacitor circuit shown in Fig. 3-25 is opened, it
exhibits characteristics distinctly different from inductive loads If i = (Em/LE)HDt sinEt (1)
due to the effects of residual electric charge in the capacitor.
D = R/2L J= —4L/CR2
In a single-phase circuit like that shown in Fig. 3-26, the
capacitor voltage lags 90° behind the current, and a peak E = —(4L/CR2)/2L, E = — (1/LCR2/4L2)
voltage exists across the capacitor terminals when the circuit
is opened. The recovery voltage appearing between the switch which yields E = J/2L
contacts immediately after the circuit is opened is equal to Generally E > 0 (1/LC > R2/4L2) is true, and oscillating transient
the difference between the capacitor residual voltage and the current flows at the natural frequency as shown below.
supply voltage. Therefore, half a cycle after the circuit opens,
the voltage between the switch contacts rises to twice the Fig. 3-27 Transient current when a capacitor circuit closes
supply voltage or higher.
In a three-phase circuit, the recovery voltage appearing
between the contacts in the first interrupted phase could rise
as high as 2.5 times the supply voltage.
Unless the breaker contacts are fully open until half a cycle
after the capacitor circuit opens, restrike of arc will occur. If the
capacitor is discharged by damped oscillation at the oscillation
frequency according to the inductance (L) and capacitance (C)
of the circuit at re-ignition, then residual peak voltage will be
left at the terminal again if the arc is quenched (current cuts
off).
If restrike of arc is repeated, the voltage could continue to rise
to the dielectric breakdown point of the capacitor.
Hence, fast-interrupting circuit breakers with quick-make, Since the natural frequency at this time is as follows: f = Z/2S,
quick-break action are recommended for this type of circuit. equation (1) yields Z = E, and so
f = —1/(LCR2/4L2)/2S, f = J/4SL
Fig. 3-25 Residual electric charge in the capacitor
Then equation (1) above yields the following equation.
i = (2Em/J)H−tR/2Lsin (J/2L)t .....................(2)
Maximum current at this time is expressed as follows:
im = (Em/—L/C)HR/JtanJ/R (3)
im = (Em/—L/C)HDxø/E (3-1)
The first wave peak W0 is expressed as follows:
Fig. 3-26 Capacitor residual voltage W0 = (2L/J)tan−1J/R W0 = ø/E ...........(4)
ø = tan−1E/D (rad)
Since the time shown in equation (4) is very short, the voltage
in equation (3) or (3)-1 is essentially V = Em.
Since H−D·ø/E is approximately 1, the peak transient inrush
Vc=Em current is derived as follows from equation (3)-1.
im | Em —C/L (5)
(Here, Em is √2/3 times the line voltage in a three-phase
circuit and is √2 times the line voltage in a single-phase
circuit.)
The preceding equations prove that transient inrush current
flowing to the capacitor is related to inductance (L), that is, it
is related to the power supply capacity and the presence or
absence of reactors connected in series with the capacitor.

69
 Selection and application
3 3-8 Selecting an MCCB for capacitor circuit

If no reactors are connected in series with the capacitor, then (4) When capacitors are connected in parallel with
the R, L, and C defined by the power supply transformer individual motor circuits to improve the power
capacity, percentage impedance and capacitance will cause factor (See Fig. 3-28.)
wild fluctuations in the inrush current factor (first wave peak/
When selecting the rated current of an MCCB, choose one
effective rated capacitor current), oscillating frequency and
where startup inrush current-time characteristics for the
damping constant. The amount of fluctuation is especially
motor will not cause the MCCB to malfunction. If capacitance
significant when it comes to selecting a rated current for the
less than 30% of the motor capacity is used here, then the
MCCB. This is why inserting reactors totaling up to 6% of the
rated current of the MCCB should be at least three times the
impedance into capacitor circuits is highly recommended for
rated current of the capacitor. This will prevent the MCCB
improving the power factor.
from malfunctioning even without series-connected reactors
Series-connected reactors are needed because the inrush
because the capacitor is installed on the secondary side of
current from other capacitors is added to the current from
the magnetic motor starter. Refer to the Technical Information
the power supply if capacitors are inserted in parallel using
for the magnetic motor starter for more details on available
multiple banks without reactors.
models and durability characteristics.
(3) Selecting an MCCB for phase advance capacitor Fig. 3-28 Capacitors connected in parallel with the motor
circuits
MCCB MS
Table 3-20 shows the rated current (In) for applicable MCCBs
at various capacitances. Since the conditions for selecting
MCCBs are aimed at preventing mistripping, first find the
effective current (Ict), that is, the transient current plus the M
steady state current 0.01s after power is turned on. If that
current (Ict) is less than 1/10 the instantaneous tripping current
of the MCCB (10 times the rated current of the MCCB) or is
more than 1.5 times the rated current of the capacitor (Icn),
then use the main current approximating that value.
In > k u Ic Ic > Ict/10 or Ic > Icn
Icn: Capacitor rated current (effective value)
(Single phase: Icn = ZC·V, three-phase: Icn = ZC·V/ √3 ) Capacitors
In: MCCB rated current (effective value)
Ict: Inrush current 0.01s after power is turned ON (effective
value)
Ic: Ict/10 or Icn min
k: 1.5 (margin coefficient for the allowable fluctuation error)
V: Line voltage (effective value)
Z: 2Sf (f: frequency (Hz) of the applicable circuit)
.OTES s 4HE VALUE OF  TIMES IS THE SUM OF THE MAXIMUM ALLOWABLE CURRENT
for the capacitor (1.3 times the rated current) and the allowable
capacitance error plus 15%.
s 4HE OSCILLATING FREQUENCY OF TRANSIENT CURRENT IS MUCH HIGHER THAN THE
fundamental harmonic. It ranges from several hundred hertz to several
kilohertz with no series-connected reactors, or less than several
hundred hertz (200 to 300Hz max.) regardless of the power supply
capacity with reactors totaling 6% of the impedance connected in
series.
s 4RANSIENT CURRENT ATTENUATION IS RELATIVELY FAST WITHOUT REACTORS
connected in series and is fairly slow with reactors connected in series.

70
 Selection and application
3-8 Selecting an MCCB for capacitor circuit
3

Table 3-20 (1) MCCB rated current application examples for single-phase capacitor equipment capacity
Rated frequency Rated voltage Rated equipment Rated current Capacitor rating Series reactor 6% MCCB rated MC type
(Hz) (V) capacity (kvar) (A) (kvar) (μF) (kvar) (mH) current (A) (reference)
50 200 1.34 6.7 1.43 100 0.09 6.06 10 SC-0
2.67 13.4 2.84 200 0.17 3.04 20 SC-4-0
3.34 16.7 3.55 250 0.21 2.43 30 SC-4-1
4.01 20.1 4.27 300 0.26 2.03 30 SC-5-1
5 25.0 5.32 374 0.32 1.63 40 SC-N1
10 50.0 10.64 748 0.64 0.81 75 SC-N2S
15 75.0 15.96 1,122 0.96 0.54 125 SC-N4
20 100.0 21.28 1,496 1.28 0.41 150 SC-N6
25 125.0 26.60 1,870 1.60 0.33 200 SC-N7
30 150.0 31.91 2,244 1.91 0.27 225 SC-N8
40 200.0 42.55 2,992 2.55 0.20 300 SC-N11
50 250.0 53.19 3,740 3.19 0.16 400 SC-N12
75 375.0 79.79 5,610 4.79 0.11 600 SC-N14
100 500.0 106.38 7,480 6.38 0.08 800 SC-N16
150 750.0 159.57 11,220 9.57 0.05 1200
200 1000.0 212.77 14,961 12.77 0.04 1500
300 1500.0 319.15 22,441 19.15 0.03 2500
400 1.07 2.7 1.14 20 0.07 30.38 5 SC-03
1.60 4.0 1.70 30 0.10 20.32 10 SC-03
2.67 6.7 2.84 50 0.17 12.18 10 SC-0
4.01 10.0 4.27 75 0.26 8.11 15 SC-05
5 12.5 5.32 94 0.32 6.50 20 SC-4-0
10 25.0 10.64 187 0.64 3.25 40 SC-N1
15 37.5 15.96 281 0.96 2.17 60 SC-N2
20 50.0 21.28 374 1.28 1.63 75 SC-N2S
25 62.5 26.60 468 1.60 1.30 100 SC-N3
30 75.0 31.91 561 1.91 1.08 125 SC-N4
40 100.0 42.55 748 2.55 0.81 150 SC-N6
50 125.0 53.19 935 3.19 0.65 200 SC-N7
75 187.5 79.79 1,403 4.79 0.43 300 SC-N11
100 250.0 106.38 1,870 6.38 0.33 400 SC-N14
150 375.0 159.57 2,805 9.57 0.22 600 SC-N16
200 500.0 212.77 3,740 12.77 0.16 800 SC-N16
300 750.0 319.15 5,610 19.15 0.11 1200
60 220 0.97 4.4 1.03 50 0.06 12.17 10 SC-03
1.94 8.8 2.06 100 0.12 6.08 15 SC-0
2.91 13.2 3.10 150 0.19 4.06 20 SC-0
3.88 17.6 4.13 200 0.25 3.04 30 SC-4-1
5 22.7 5.32 258 0.32 2.36 40 SC-N1
10 45.5 10.64 515 0.64 1.18 75 SC-N2S
15 68.2 15.96 773 0.96 0.79 125 SC-N4
20 90.9 21.28 1,030 1.28 0.59 150 SC-N6
25 113.6 26.60 1,288 1.60 0.47 200 SC-N7
30 136.4 31.91 1,546 1.91 0.39 225 SC-N8
40 181.8 42.55 2,061 2.55 0.30 300 SC-N11
50 227.3 53.19 2,576 3.19 0.24 400 SC-N11
75 340.9 79.79 3,864 4.79 0.16 600 SC-N14
100 454.5 106.38 5,152 6.38 0.12 800 SC-N14
150 681.8 159.57 7,728 9.57 0.08 1200
200 909.1 212.77 10,303 12.77 0.06 1500
300 1363.6 319.15 15,455 19.15 0.04 2500
440 1.55 3.5 1.65 20 0.10 30.45 5 SC-03
2.33 5.3 2.48 30 0.15 20.26 10 SC-0
3.11 7.1 3.31 40 0.20 15.18 10 SC-0
3.88 8.8 4.13 50 0.25 12.17 15 SC-4-0
5 11.4 5.32 64 0.32 9.44 20 SC-4-0
10 22.7 10.64 129 0.64 4.72 40 SC-N1
15 34.1 15.96 193 0.96 3.15 60 SC-N2
20 45.5 21.28 258 1.28 2.36 75 SC-N2S
25 56.8 26.60 322 1.60 1.89 100 SC-N3
30 68.2 31.91 386 1.91 1.57 125 SC-N4
40 90.9 42.55 515 2.55 1.18 150 SC-N6
50 113.6 53.19 644 3.19 0.94 175 SC-N7
75 170.5 79.79 966 4.79 0.63 300 SC-N11
100 227.3 106.38 1,288 6.38 0.47 350 SC-N12
150 340.9 159.57 1,932 9.57 0.31 600 SC-N14
200 454.5 212.77 2,576 12.77 0.24 700 SC-N16
300 681.8 319.15 3,864 19.15 0.16 1000

71
 Selection and application
3 3-8 Selecting an MCCB for capacitor circuit

Table 3-20 (2) MCCB rated current application examples for three-phase capacitor equipment capacity
Rated frequency Rated voltage Rated equipment Rated current Capacitor rating Series reactor 6% MCCB rated MC type
(Hz) (V) capacity (kvar) (A) (kvar) (μF) (kvar) (mH) current (A) (reference)
50 200 1.34 3.9 1.43 100 0.09 6.06 10 SC–03
2.67 7.7 2.84 200 0.17 3.04 15 SC–03
3.34 9.6 3.55 250 0.21 2.43 15 SC–03
4.01 11.6 4.27 300 0.26 2.03 20 SC–03
5 14.4 5.32 374 0.32 1.63 30 SC–4–0
10 28.9 10.64 748 0.64 0.81 50 SC–N1
15 43.3 15.96 1,122 0.96 0.54 75 SC-N2S
20 57.7 21.28 1,496 1.28 0.41 100 SC–N3
25 72.2 26.60 1,870 1.60 0.33 125 SC-N4
30 86.6 31.91 2,244 1.91 0.27 150 SC–N4
40 115.5 42.55 2,992 2.55 0.20 175 SC–N7
50 144.3 53.19 3,740 3.19 0.16 225 SC–N8 N10
75 216.5 79.79 5,610 4.79 0.11 350 SC–N11
100 288.7 106.38 7,480 6.38 0.08 500 SC–N12
150 433.0 159.57 11,220 9.57 0.05 700 SC–N14
200 577.4 212.77 14,961 12.77 0.04 900
300 866.0 319.15 22,441 19.15 0.03 1400
400 1.07 1.5 1.14 20 0.07 30.38 5 SC–03
1.60 2.3 1.70 30 0.10 20.32 5 SC–03
2.67 3.9 2.84 50 0.17 12.18 10 SC–03
4.01 5.8 4.27 75 0.26 8.11 10 SC–03
5 7.2 5.32 94 0.32 6.50 15 SC–03
10 14.4 10.64 187 0.64 3.25 30 SC–4–0
15 21.7 15.96 281 0.96 2.17 40 SC-N1
20 28.9 21.28 374 1.28 1.63 50 SC–N1
25 36.1 26.60 468 1.60 1.30 60 SC-N2
30 43.3 31.91 561 1.91 1.08 75 SC–N2S
40 57.7 42.55 748 2.55 0.81 100 SC–N3
50 72.2 53.19 935 3.19 0.65 125 SC–N4
75 108.3 79.79 1,403 4.79 0.43 175 SC–N7
100 144.3 106.38 1,870 6.38 0.33 225 SC–N8 N10
150 216.5 159.57 2,805 9.57 0.22 350 SC–N11
200 288.7 212.77 3,740 12.77 0.16 500 SC–N12
300 433.0 319.15 5,610 19.15 0.11 700 SC–N14
60 220 0.97 2.5 1.03 50 0.06 12.17 5 SC–03
1.94 5.1 2.06 100 0.12 6.08 10 SC–03
2.91 7.6 3.10 150 0.19 4.06 15 SC–03
3.88 10.2 4.13 200 0.25 3.04 20 SC–03
5 13.1 5.32 258 0.32 2.36 20 SC–03
10 26.2 10.64 515 0.64 1.18 40 SC–N1
15 39.4 15.96 773 0.96 0.79 60 SC-N2
20 52.5 21.28 1,030 1.28 0.59 100 SC–N2S
25 65.6 26.60 1,288 1.60 0.47 100 SC-N3
30 78.7 31.91 1,546 1.91 0.39 125 SC–N4
40 105.0 42.55 2,061 2.55 0.30 175 SC–N7
50 131.2 53.19 2,576 3.19 0.24 200 SC–N7
75 196.8 79.79 3,864 4.79 0.16 300 SC–N11
100 262.4 106.38 5,152 6.38 0.12 400 SC–N12
150 393.6 159.57 7,728 9.57 0.08 600 SC–N14
200 524.9 212.77 10,303 12.77 0.06 800 SC–N16
300 787.3 319.15 15,455 19.15 0.04 1200
440 1.55 2.0 1.65 20 0.10 30.45 5 SC–03
2.33 3.1 2.48 30 0.15 20.26 5 SC–03
3.11 4.1 3.31 40 0.20 15.18 10 SC–03
3.88 5.1 4.13 50 0.25 12.17 10 SC–03
5 6.6 5.32 64 0.32 9.44 10 SC–03
10 13.1 10.64 129 0.64 4.72 20 SC–03
15 19.7 15.96 193 0.96 3.15 30 SC-4-1
20 26.2 21.28 258 1.28 2.36 40 SC–N1
25 32.8 26.60 322 1.60 1.89 50 SC-N1
30 39.4 31.91 386 1.91 1.57 60 SC–N2
40 52.5 42.55 515 2.55 1.18 100 SC–N2S
50 65.6 53.19 644 3.19 0.94 100 SC–N3
75 98.4 79.79 966 4.79 0.63 150 SC–N5, N5A
100 131.2 106.38 1,288 6.38 0.47 200 SC–N7
150 196.8 159.57 1,932 9.57 0.31 300 SC–N11
200 262.4 212.77 2,576 12.77 0.24 400 SC–N12
300 393.6 319.15 3,864 19.15 0.16 600 SC–N14

72
 Selection and application
3-9 MCCBs for semiconductor circuit
3

3-9 MCCBs for semiconductor circuit 3-9-1 Faults and overcurrents in thyristor
Circuits containing semiconductor devices such as thyristors converters
and diodes differ in the following respects: The possible causes of overcurrents in thyristor converters
s 4HE CURRENT mOWING THROUGH THE -##" DEPENDS ON WHERE can be broadly classified into two categories: internal faults
the MCCB is installed in the circuit. in the converters, and those external to the converters. Table
s 4HE FAULT CURRENT DEPENDS ON FAULT MODES 3-21 lists the typical possible causes of overcurrents in
s 4HE OVERCURRENT CAPACITY OF SEMICONDUCTOR DEVICES IS LOWER line- commutated thyristor converters and their associated
than that of other electrical apparatus. conditions. Fig. 3-29 shows examples of the path of
Allowance should be made for these characteristics when overcurrent flow.
selecting an MCCB.
Table 3-21 Possible causes of overcurrents in line-commutated thyristor converters

Causes of overcurrent Overcurrent conditions

Category Phenomena Possible cause During conversion During inversion
Internal Misfiring Thyristors fail to fire. Suspect a Decreased output voltage. If some of When all SCRs in one arm misfire, com-
faults broken wire in the gate circuit the SCRs connected in parallel misfire, mutation fails, resulting in a short circuit
or a fault in the controller. the remaining SCRs in that arm carry an on the DC side.
overcurrent. If some SCRs in one arm misfire, the nor-
mal SCRs in that arm carry an overcur-
rent.

Faulty ignition SCRs fire when they should If SCRs are connected in parallel, current Commutation fails, resulting in a short
maintain forward blocking. concentrates in the SCRs that misfire, circuit occurring on the DC side.
Suspect an excessive forward resulting in an overcurrent.
voltage, excessive dv/dt, or
gate noise.
Device break- A short circuit has resulted A short circuit has occurred in the input An AC interphase short circuit generated
down from the loss of SCR forward AC source. a backward current that caused a transi-
blocking capability. Suspect an tion to commutation failure, resulting in a
excessive junction tempera- short circuit on the DC side.
ture or overvoltage input.
External Commutation Suspect power failure or a With an inductive load, current flows The loss of the commutating power
faults failure broken wire in the power sup- through the arm that had been turned on source causes a commutation failure,
ply circuit. until loss of the power source for a rela- resulting in a short circuit on the DC side.
tively long period of time raises junction
temperature.
Short circuit in Suspect a short circuit in the A short circuit in the AC input source. The Commutation fails as the AC voltage
load side DC circuit or flashover in the overcurrent flowing through the SCRs required for commutation is lost, but no
DC motor. varies with the short-circuit point, or the overcurrent flows through the SCRs.
presence or absence of a DC reactor.

Table 3-21 and Fig. 3-29 show that, to protect normal devices, provides two modes: one in which the thyristor converter is run
an overcurrent protection device must be installed, for each as a conversion (driving the DC motor), and one in which the
element (arm) in the conversion or on the AC side, for each thyristor converter is run as an inversion (regenerative braking
element in an inversion or on the DC side. of the DC motor). Installation of protective devices should be
The Ward-Leonard thyristor configuration in which the speed examined by considering possible failures in these two modes.
of the DC motor is controlled by thyristor phase control
Fig. 3-29 Example of the path of overcurrent flow in thyristor converters
During conversion During inversion Commutation failure
Device breakdown

M M

Short-circuit

Commutation failure due to loss of

the power source
M

Commutation failure due to

faulty ignition

73
 Selection and application
3 3-9 MCCBs for semiconductor circuit

3-9-2 MCCB rated current

When an MCCB is used as a protective device, it is installed on the DC side. Hence, the location of the MCCB should be
on either the AC or DC side. The current that flows through the determined with the importance of the load equipment and
MCCB may differ depending on the side in which it is installed. economy taken into consideration.
Remember this point when selecting an MCCB rated current Table 3-22 indicates the circuit configurations and component
rating. current values of thyristor converters. Select an MCCB with
With three-phase bridge circuits, installing an MCCB on the a current rating higher than the effective circuit current,
AC side may be more economical because an MCCB with depending on its installation location. A 20% margin is
a smaller current rating can be used in this setup. The type recommended.
of failure may dictate, however, that the MCCB be installed

Fig. 3-22 Circuit configurations and component current of thyristor converters

Circuit configuration

I Id I Id
I =Ia
Ia Ia
I =Ia=Id

Id
Current waveform

ip ip ip ip

1/2f 1/2f 1/2f 1/3f

Element (arm)

1/f 1/f 1/f 1/f

Average: Ia (av) 1 S ip Average: Ia (av) 1 S ip Average: Ia (av) 1 S ip Average: Ia (av) 1 S ip

Current Ia

Effective: Ia (eff) 1 ip Effective: Ia (eff) 1 ip Effective: Ia (eff) 1 ip Effective: Ia (eff)

2 2 2

— 1 + — 3 ip | 0.553ip
6 4S
Current waveform

ip ip ip ip

1/f 1/f 1/f 1/f

DC side

Average: Id (av) 1 S ip Average: Id (av) 2 S ip Average: Id (av) 2 S ip Average: Id (av) 3 S ip

Current Id

Effective: Id (eff) 1 ip Effective: Id (eff) 1 ip Effective: Id (eff) 1 ip Effective: Id (eff)

2 —2 —2

— 3 + 3 — 3 ip | 0.956ip
6 4S
Current waveform

ip ip ip ip
AC side

1/f 1/f
1/f
1/f

Average: I (av) 1 Average: I (av) 1 1 Effective: I (eff)

Current I

S ip S ip Effective: I (eff)
—2
ip
Effective: I (eff) 1 ip
2
Effective: I (eff) 1 ip
2 — 2 + 2 — 3 ip | 0.78ip
6 4S

Note: The loads are resistive, and the conduction angle of the device is 180°.

74
 Selection and application
3-9 MCCBs for semiconductor circuit
3

3-9-3 Protecting thyristors from overcurrent Fig. 3-31 Coefficient for converting to effective values

The following methods are commonly used to protect 2.0

Ip
semiconductor devices such as thyristors and diodes from Ieff=
K
overcurrent: 1.9

Conversion coefficient (K)

Direct protection Current-limiting fuses 2(2n-1)
1.8 K=
Circuit breakers n
Circuit protectors
1.7
High-speed DC circuit breakers Ip
Indirect protection DC current limiting control 0 2 3 4 5
1.6
Gate control
These combinations can protect devices from all types of 1.5
overcurrent, but they are a very costly method. It is best to
achieve a balanced system that considers the importance of 1.4
the equipment, the desired reliability, the cost performance,
the potential faults and the probability of those faults when 0.01 0.02 0.03 0.05 0.07 0.1 0.2 0.3 0.5 0.7 1 2 3 5 7 10
designing a protective system for semiconductor equipment. Time (seconds)
When devices must be fully protected in large-capacity
replacement equipment (in which devices are expensive) and (2) Protection in the short-circuit region
critical equipment, for example, it may be quite expensive, If a short circuit in the load occurs during forward conversion
but the protective combination described above is sometimes (rectification) or if an arm short circuit results from device
needed for added assurance. In equipment where cost is breakdown, the overcurrent must be interrupted in an
critical on the other hand, every effort must be made to at least extremely short period of time to protect the normal devices
protect against the most likely faults. against the resulting large current.
In such a region, a protective device should be selected to
(1) Protection in the overload current region meet the following relation with respect to the allowable limit
The overcurrent immunity of a thyristor, as represented in value of I2t of the devices:
Fig. 3-30, is expressed with the period of time over which the Allowable I2t of device > I2t flowing through device when the
thyristor can tolerate the peak value of positive half cycles of a protective device trips
sinusoidal current flowing through it. Fuses for protecting semiconductors provide better current-
The overload characteristics indicated by the solid lines limiting performance than MCCBs, that is, fuses are better
suggest that the junction temperature remains within tolerable suited for protecting thyristors against overcurrent caused by
limits even when an overcurrent flows. The limit characteristic short circuits.
curves indicated by the dotted lines, generally known as
allowable surge-on current limits, indicate limits of the thermal (3) Use of MCCBs on the AC side of thyristors
immunity of the device. Hence, the appropriate protective When MCCBs are installed on the AC side of a converter
device to be selected must be capable of interrupting the as shown in Fig. 3-32, their primary duty will be interrupting
current within the limits of time shown in Fig. 3-30. When the fault current during forward conversion on rectification.
making this selection, however, remember that the operating From the standpoint of protection coordination with devices,
characteristics of MCCBs (including current-limiting fuses) instantaneous trip type MCCBs will be more suitable than
are generally expressed using effective values of sinusoidal MCCBs for line protection.
current, but in the case shown in Fig. 3-30, characteristics are An instantaneous trip type circuit breaker is tripped within
expressed using the peak value of sinusoidal current. one cycle of any current exceeding its preset trip current Ii.
It is therefore necessary to convert the overcurrent immunity Accordingly, if MCCB preset currents are specified as shown
characteristics expressed on the effective value base to in (a) and (b) in Fig. 3-33, overcurrent protection is available in
compare with the characteristics of the protective device. Fig. region B.
3-31 shows an example of a coefficient curve for converting to If the instantaneous trip characteristics of an MCCB are preset
effective values. as indicated by 2 in (a), Fig. 3-33, an additional protective
relay such as an overcurrent relay will be needed to provide
Fig. 3-30 Overcurrent immunity characteristics of semiconductor
protection in region A.
devices
There will be no problem as long as the maximum current
Rated load flowing through the circuit does not enter region C. Circuits
Overload characteristics in which fault currents are likely to flow in region C, however,
Limit characteristics would benefit by installation of reactors to suppress the fault
current, or fuses for protecting semiconductors.
From no load
t
From a 50% load Fig. 3-32 MCCBs for AC applications
From a 100% load

No load
Rated load

MCCB
i

75
 Selection and application
3 3-9 MCCBs for semiconductor circuit

Any examination of the scheme of protection coordination (4) Use of MCCBs on the DC side of thyristors
between MCCBs and devices should allow conversion of
When MCCBs are installed on the DC side of a converter Fig.
the device overcurrent immunity into effective values for
3-34, their primary duty will be interrupting the fault current
comparison. For example, in a three-phase bridge like that
that flows through the circuit when commutation fails during
shown in Fig. 3-32, the currents through the MCCBs differ
inversion in a thyristor Ward-Leonard or similar configuration.
from that in devices and they must be compared on the same
Typically, an instantaneous trip type circuit breaker is used with
current base.
the instantaneous trip current set to about two or three times
Fig. 3-33 Typical protection coordination curves
its rating. The scheme of protection coordination is considered
in terms of I2t.
(a)
Fig. 3-34 Using an MCCB in a DC circuit
5 4
t 2 Faulty device
1
MCCB

AC 
3

Since, in the circuit configuration shown in Fig. 3-34, the fault

currents flowing through the MCCB and the devices are equal,
it is necessary to meet the relation: allowable thyristor I2t >
i MCCB maximum interrupting I2t of the MCCB.

Region B Region C
Region A
1. Thyristor overcurrent immunity characteristics
2. Instantaneous trip type circuit breaker operating characteristics
3. Semiconductor protection fuse operating characteristics
4. Overcurrent relay operating characteristics
5. Motor breaker operating characteristics

(b)

t 2
1

i
Region B Region C

1. Thyristor overcurrent immunity characteristics

2. Instantaneous trip type circuit breaker operating characteristics
3. Semiconductor protection fuse operating characteristics

76
 Selection and application
3-10 Protecting SSCs using MCCBs or MMSs
3

3-10 Protecting SSCs using MCCBs or

MMSs
When an MCCB is used to protect a solid-state contactor
(SSC), protection over the entire range of its overload
region to the short-circuit region would be difficult to achieve
with an MCCB alone. To ensure complete protection of the
SSC with an MCCB, the MCCB should be combined with a
thermal overload relay and current-limiting fuse, or any other
appropriate protective device.

3-10-1 For heater (resistive load) circuits

Table 3-23 lists recommended combinations of MCCBs and
SSCs for heater control purposes. These combinations enable
MCCBs to protect SSCs in region B, and current-limiting
fuses to protect in region C (Fig. 3-33). The SSCs can thus be
protected against short-circuit currents two times higher than
the SSC’s rated current and lower than the current-limiting Solid-state contactor
fuse breaking capacity with MCCBs.

Table 3-23 Protecting SSCs for heater circuits using MCCB (short-circuit region)

Rated voltage SSC type MCCB Fuse

Type Icu (kA) Type I2t u103A2S) Icu (kA)
230V AC SS03† BW32SAQ-3P005 5 CR2LS-10 0.04 100
SS08† BW32SAQ-3P010 5 CR2LS-10 0.04 100
SS20† BW32SAQ-3P040 5 CR2LS-30 0.35 100
SS30† BW32SAQ-3P060 5 CR2LS-50 0.85 100
SS40† BW32SAQ-3P080 10 CR2LS-70 2.3 100
SS50† BW63SAQ-3P120 10 CR2LS-100 4.0 100
SS80† BW125JAQ-3P450 50 CR2L-140 7.0 100
SS120† BW250JAQ-3P600 50 CR2L-200 17 100
400V AC SS30†H BW32SAQ-3P060 2.5 CR6L-50 1.8 100 *1
SS50†H BW63SAQ-3P120 7.5 CR6L-100 7.0 100 *1
SS80†H BW125JAQ-3P450 30 CR6L-200 30 100 *1
SS120†H BW250JAQ-3P600 30 CR6L-200 30 100 *1
.OTES s )NDICATES 33#S MOUNTED ON STANDARD COOLING lNS
s 5SE AN "7*!1 0 FOR 33† applications with through current at or below 100A.
s 5SE A TWO POLE -##" IN SINGLE PHASE CIRCUIT 33# APPLICATIONS OR A THREE POLE -##" IN THREE PHASE CIRCUIT 33# APPLICATIONS
*1 Breaking capacity at 600V AC.

77
 Selection and application
3 3-10 Protecting SSCs using MCCBs or MMSs

3-10-2 Motor circuits

Table 3-24 shows various combinations that are available for
motor circuit SSC control. Fig. 3-33 shows that a manual motor
starter (MMS) protects regions A and B while a current-limiting
fuse protects region C. This combination can protect the SSC
from anything from overloading to short-circuiting.

Table 3-24 Protecting SSCs for heater circuits using MCCB

(short-circuit region)

Rated voltage Motor capacity SSC Type Manual motor starter (MMS) Fuse
(kW)
Type Breaking capacity (kA) Type Breaking capacity (kA)
250V AC
230V AC 0.2 SS03† BMSRSB-1P6 100 CR2L(S)-10 100
3-phase 0.4 SS08† BM3RSB-2P5 *1 100 CR2L(S)-10 100
0.75 SS20† BM3RSB-004 100 CR2L(S)-30 100
1.5 SS30† BM3RSB-6P3 100 CR2L(S)-50 100
2.2 SS40† BM3RSB-010 100 CR2L(S)-75 100
3.7 SS50† BM3RSB-016 100 CR2L(S)-100 100
5.5 SS80† BM3RSB-025 50 CR2L-140 100
7.5 SS802 BM3RSB-032 50 CR2L-175 100
7.5 SS120† BM3RSB-032 50 CR2L-175 100
400V AC 1.5 SS30†H BM3RSB-004 100 CR6L-30 100 *2
3-phase 2.2 SS30†H BM3RSB-6P3 100 CR6L-50 100 *2
3.7 SS30†H BM3RSB-010 100 CR6L-50 100 *2
5.5 SS50†H BM3RSB-013 50 CR6L-75 100 *2
7.5 SS50†H BM3RSB-016 50 CR6L-100 100 *2
15 SS80†H BM3RSB-032 50 CR6L-200 100 *2
15 SS120†H BM3RSB-032 50 CR6L-200 100 *2
Notes: Indicates SSCs mounted on standard cooling fins.
*1 Overload protection is not available in some regions.
*2 Breaking capacity at 600V AC.

78
 Selection and application
3-11 Protecting inverter circuits using MCCBs
3

3-11 Protecting inverter circuits using MCCBs

3-11-1 Inverter circuits
Inverters usually rely on internal overcurrent protection. Therefore,
the MCCB must protect the system up to the power supply
terminal for the main circuit and must not inadvertently trip while
the inverter is operating normally.

Rated voltage Motor Full load MCCB rated current (A) Rated voltage Motor Full load MCCB rated current (A)
output current With DC Without DC output current With DC Without DC
(kW) (A) reactor reactor (kW) (A) reactor reactor
200V AC 0.1 0.68 5 5 400V AC 0.4 1.15 5 5
3-phase 0.2 1.3 3-phase 0.75 1.8
0.4 2.3 1.5 3.5 10
0.75 3.5 10 2.2 4.8 15
1.5 6.9 10 15 3.7 7.8 10 20
2.2 9.5 20 5.5 10.5 15 30
3.7 15.5 20 30 7.5 13.5 20 40
5.5 21 30 50 11 20 30 50
7.5 27.5 40 75 15 27 40 60
11 40 50 100 18.5 34 75
15 54 75 125 22 42 50 100
18.5 68 100 150 30 58 75 125
22 84 175 37 69 100
30 116 150 200 45 83 150
37 137 175 250 55 100 125 200
45 166 200 300 75 136 175 -
55 200 250 350 90 166 200
75 272 350 - 110 190 250
90 332 400 132 225 300
110 380 500 160 273 350
Note: *1 U 200 342 500
220 376
280 600
315 800
355
400 1200
450
500
Note: For the MCCB types, the rated current values recommended for 50˚C or lower
panel inside temperature are shown. Select an actual type according to the
facility short-circuit interrupting capacity.

79
 Selection and application
3 3-12 MCCBs for high frequency circuits

3-12 MCCBs for high frequency circuits Table 3-26 MCCBs for 400Hz circuits
Specify 400Hz when ordering an MCCB for a 400Hz circuit.
Hydraulic-magnetic type and solid-state trip type MCCBs
cannot be used in 400Hz circuits because their characteristics Frame Type Icu (kA) Rated current
size (A)
would vary considerably. 400V AC 230V AC
Since the instantaneous trip current of standard 125AF BW125JAG 30 50 15, 20, 30, 40, 50,
thermalmagnetic MCCBs models (magnetic element) will 60, 75, 100
BW125RAG 50 100
increase by 1.5 to 2.5 times the cataloged value around
400Hz, circuit breakers specially designed for use in 400Hz 250AF BW250EAG 18 30 125, 150, 160,
175, 200, 225
circuits should be used (these models are available on BW250JAG 30 50
request). Because highcurrent rating MCCB (400AF to 800AF) BW250RAG 50 100
generate increased heat due to the skin effect, their load
400AF *1 BW400EAG 30 50 250, 300, 350
capacity must be derated 20% to 30%.
Table 3-26 lists some FUJI MCCBs recommended for use in BW400SAG 36 85
400Hz circuits. BW400RAG 50 100
Note: *1 Use a load capacity 20 to 30% lower because of the skin effect.

80
 Selection and application
3-13 MCCBs for DC circuit applications
3

3-13 MCCBs for DC circuit applications Operating characteristic changes for DC circuit application
While MCCBs are designed for an AC circuit, some may be Trip Inverse time-delay Instantaneous trip Operating
used in a DC circuit. The DC rating is cited in the catalog for device trip characteristic characteristics characteristic curve

those applicable to a DC circuit. If a MCCB adjusted for AC is Thermal- None The instantaneous trip
magnetic current is higher than
to be used in a DC environment, the operating characteristics

Operating time
that for an AC circuit.
DC
will change as indicated in the table on the right. Therefore, The rate of variation
depends on the AC
FAB adjusted for DC shall be used for a DC load. Further, due
ampere-frame size,
to the absence of a zero-crossing point, it is more difficult to rated current and Current
break a DC current than an AC current in high-voltage levels. Hydraulic- The minimum
model. The trip
current can be as high
Therefore, standard products cannot be used. magnetic operating current at
as 140% of the AC

Operating time
DC is
In such a case, it is necessary to use a breaker dedicated for value. DC
about 110–140% of
use with a DC high voltage. that for AC. AC
ELCB cannot be used because it cannot detect leakage of DC Current
current.
Solid state Not applicable

Table 3-27 MCCBs DC line up

Rated voltage Frame size
25/32 50 63 100/125 160 200/250 400 630 800
DC 125V BW32SBG BW50SBG BW63SBG
10/10 10/10 10/10
250V BW50EAG BW63EAG BW100EAG BW160EAG BW250EAG BW400EAG BW630EAG BW800EAG
"7%!1
C2 C2 C2
2.5/2 2.5/2 5/3 10/5 10/5 20/10 20/10 20/10
BW32SAG BW50SAG BW63SAG BW125JAG BW160JAG BW250JAG BW400SAG
"73!1 "73!1 "73!1 "7*!1 C2 "7*!1 C2
C2 C2 C2
2.5/2 5/3 5/3 15/8 20/10 20/10 20/10
BW50RAG BW63RAG BW125RAG BW160RAG BW250RAG BW400RAG BW630RAG BW800RAG
"72!1 C2 "72!1 C2 "72!1 C2 "72!1 C2 "72!1 C2
C2 C2
5/3 5/3 40/20 30/15 30/15 40/20 40/20 40/20
BW50HAG BW125HAG BW250HAG BW400HAG BW630HAG BW800HAG
"7(!1 C2 "7(!1 C2 "7(!1 C2
40/20 40/20 40/20 40/20 40/20 40/20
400V BW32SAG BW50SAG BW63SAG BW100EAG
-3P C4 -3P C4 -3P C4 -3P C4
2.5/- 2.5/- 2.5/- 5/-
500V BW400EAG BW630EAG BW800EAG
-3P -3P -3P
20/- 20/- 20/-
BW125JAG BW250JAG BW400SAG
-3P C5 -3P C5 -3P
10/- 10/- 20/-
BW125RAG BW250RAG BW400RAG BW630RAG BW800RAG
-3P C5 -3P C5 -3P -3P -3P
20/- 20/- 40/- 40/- 40/-
BW400HAG BW630HAG BW800HAG
-3P -3P -3P
40/- 40/- 40/-
600V BW125JAG BW250JAG
-3P CP -3P CP
3/- 3/-
BW 50SBG BW 63SBG BW 125RAG BW 250JAG BW 400RAG BW 630RAG BW 800RAG
-3P C6 -3P C6 -4P C6 -4P C6 -4P -4P -4P
10/- 10/- 25/- 25/- 40/- 40/- 40/-
BW 250RAG BW 400HAG BW 630HAG BW 800HAG
-4P C6 -4P -4P -4P
40/- 40/- 40/- 40/-
750V BW 400RAG BW 630RAG BW 800RAG
-3P CP -3P CP -3P CP
10/5 10/5 10/5
1000V BW 400RAG BW 630RAG BW 800RAG
-4P CP -4P CP -4P CP
5/5 5/5 5/5
Note: If there is no DC-specific model code such as “C2,” “C5” and “C6” at the end of the type description, a standard product can be used for both AC and DC. Only DC250V is indicated for
DC rating (DC125V is indicated for BW32SBG, BW50SBG and BW63SBG). For those adjusted to DC circuit, please specify “C2” (DC250V rating), “C5” (DC500V rating), or “C6” (DC600V
rating) at the end of the type description.

81
 Selection and application
3 3-13 MCCBs for DC circuit applications

Table 3-27 Disconnect switches line up

Rated voltage Frame size
32 50 63 100 125 250 400 630 800
DC 250V BW32SAS BW50SAS BW63SAS BW100EAS BW125JAS BW250EAS BW400EAS BW630EAS BW800EAS
BW125RAS BW250RAS BW630RAS
400V BW32SAS- BW50SAS BW63SAS BW100EAS
3P C4 -3P C4 -3P C4 -3P C4
500V BW125JAS BW250EAS BW400EAS BW630EAS BW800EAS
-3P C5 -3P C5 -3P -3P -3P
BW125RAS BW250RAS BW400RAS BW630RAS BW800RAS
-3P C5 -3P C5 -3P -3P -3P
600V BW125RAS BW250RAS BW400RAS BW630RAS BW800RAS
-4P C6 -4P C6 -4P -4P -4P
650V BW50SAS
-3P 0A0 5
700V

750V BW400RAS BW630RAS BW800RAS

-3P CP -3P CP -3P CP
800V

1000V BW400RAS BW630RAS BW800RAS

-4P CP -4P CP -4P CP

Note 1) While 400 - 800AF can be used for the standard products of DC500V(3-pole item) and DC600V(4-pole item), only DC250V is cited on the nameplate. If it is necessary to indicate
DC500V or DC600V, please specify “C5” or “C6” at the end of the type description.

Example of wiring diagram

In the circuit exceeding DC250V, it is necessary to ensure the
switching performance and breaking performance by conduct-
ing serial connection of contacts for 3-pole or 4-pole items.
Note: The connection method may change depending on the
type.
Please confirm the details on the pages listing the characteris-
tics and external form of each product.

2P (250 V) 3P (251 to 750V DC 4P (251 to 1000V DC)

N P N P N P

Load
Load

Load

82
 Selection and application
3-14 MCCBs for UPS applications
3

3-14 MCCBs for UPS applications

Select an MCCB with 1.2 times the UPS (uninterrupted power
supply) output, and use an MCCB with the same capacity at
the input side. Consider the following points when selecting an
MCCB.
UPS overload withstand:
125% for 10 minutes
150% for 1 minute
With overcurrent (including short-circuit current) at the load
side exceeding 160% of the operating current, the UPS will
switch to a backup circuit without tripping the MCCB.

83
 Selection and application
3 3-15 MCCBs for servo amplifier applications

3-15 MCCBs for servo amplifier applications

Install an MCCB on the primary side of the servo amplifier for
power supply switching and to prevent damage caused by short-
circuit current.
Table 3-29 lists the types that are available for servo amplifier
applications. Servo amplifiers are equipped with overcurrent
(output side) and other protective functions.

Table 3-29 MCCBs for servo amplifiers (FALDIC-D and -E series)

Input power Output FALDIC-D and -E series FALDIC-E series MCCB type ELCB (reference)
supply [kW] type
Three-phase 0.05 Standard series RYS500S3-††† Standard series RYB500S3-VBC BW32AAG-3P003 EW32SAG-3P003
230V 100V series
0.1 RYS101S3-††† RYB101S3-VBC
0.2 RYS201S3-††† RYB201S3-VBC BW32AAG-3P005 EW32EAG-3P005
0.4 RYS401S3-††† RYB401S3-VBC BW32AAG-3P010 EW32EAG-3P010
0.75 RYS751S3-††† RYB751S3-VBC BW50EAG-3P015 EW50EAG-3P015
1 RYS102S3-††† BW50EAG-3P015 EW50EAG-3P015
1.5 RYS152S3-†††
2 RYS202S3-††† BW50EAG-3P030 EW50EAG-3P030
3 RYS302S3-††† BW50EAG-3P040 EW50EAG-3P040
4 RYS402S3-††† BW50EAG-3P050 EW50EAG-3P050
5 RYS502S3-†††
0.5 Low-base speed RYS501A3-††† BW50EAG-3P015 EW50EAG-3P015
series
1.5 RYS152A3-†††
2.5 RYS252A3-††† BW50EAG-3P040 EW50EAG-3P040
2.9 Medium capacity RYS292M3-††† BW50EAG-3P040 EW50EAG-3P040
D- series
4 RYS402M3-††† BW50EAG-3P050 EW50EAG-3P050
5.5 RYS552M3-†††
7.5 RYS752M3-††† BW100EAG-3P075 EW100EAG-3P075
11 RYS113M3-††† BW100EAG-3P100 EW100EAG-3P100
15 RYS153M3-††† BW125JAG-3P125 EW125JAG-3P125

84
 Selection and application
3-16 Ground fault protection in system applications
3

3-16 Ground fault protection in system applications

3-16-1 Grounding methods and ground fault protection in
system applications
There are three possible grounding systems for low-voltage circuits: direct
grounding, neutral point resistor grounding or no grounding at all.
Direct grounding systems are widely used in Europe and the United States.
Unfortunately, direct grounding causes ground circuit impedance to drop
and ground fault current to rise rather steeply when there is a ground fault,
and the result is often a malfunction.
Table 3-30 provides an overall description of all grounding systems.

Table 3-30 Grounding systems for low-voltage circuits

Method Description Main circuit Sample applications

Direct Direct grounding systems run a ground to a neutral Used to reduce voltage
grounding *1 point in order to minimize any increase in the electric Fig. a to ground for safety in
potential to ground with mixed high and low voltage Main transformer Low voltage building wiring.
grounding.
Since ground fault current on a single wire is rather
large with direct grounding systems, it is much easier
to detect ground faults, and any increase in the electric
potential to ground is relatively small with a sound L L M
E
phase. This is quite helpful for system safety. There is Single-phase Three-phase
also no real danger of abnormal voltage occurring due load load
to resonance or intermittent grounding as is often the
case with no grounding at all. As a rule, a faulty circuit
is shut down as quickly as possible when a ground
fault occurs.
Resistor Ground fault current is significant with direct Factory wiring
grounding grounding, and no grounding systems may be to Fig. b Circuits shutting down
(low to mid blame for circuit problems. However, low-voltage wiring Main transformer Low voltage immediately when a
impedance systems tend to have low charging current to ground ground fault occurs
grounding) and the sensitivity of protective relays makes it hard very often shuts down
to choose a feeder for ground faults in that case. The operations in factories,
resistor grounding method shown in Fig. b then is a Ground so greater emphasis
better choice for this application. Unfortunately, resistor E resistance M is being placed on
grounding does not completely eliminate possible Contact prevention Three-phase suppressing ground
abnormal voltages or higher electric potential to plate load fault current to prevent
ground even with appropriate phases if a ground fault fires and explosions.
occurs.
No grounding A ground fault in a factory power supply instantly trips Factory wiring
(high- circuits that can shut down operations. No grounding is Fig. c Circuits shutting down
impedance generally used in 3 to 6kV high-voltage wiring systems immediately when a
Contact prevention plate
grounding) *2 because ground fault current continues to flow here ground fault occurs
Main transformer Low voltage
without high-speed tripping as long as the ground very often shuts down
fault current is kept low enough to prevent damage to operations in factories,
the equipment and to prevent the fault from becoming so greater emphasis
more widespread. is being placed on
Nearly all motors in a factory are 3-phase loads that M suppressing ground
do not normally require a neutral line, and even an Three-phase fault current to prevent
ungrounded system like that shown in Fig. c can be E fires and explosions.
load
used in a 400V wiring system. This makes it hard to
When using a
detect ground faults, however, so steps must be taken
grounding
to handle abnormal voltages when they occur.
transformer

Notes: *1 The TN system is mainly used in Europe (except for France) while the s 4. # 3 4HE NEUTRAL CONDUCTOR AND PROTECTIVE CONDUCTOR FUNCTIONS
TT system is mainly used in Japan and France for direct grounding. are combined into a single conductor in one part of a TN-S system.
A TN system is grounded to one point. Here, all exposed conductive Table 3-31 shows a comparison of various characteristics for
parts at the load side are grounded at one point through protective grounding systems as well as precautions regarding their use.
conductors. The neutral conductor and protective conductor are A TT system is grounded to one point in the system. All exposed
handled in one of the following ways. conductive parts at the load side are grounded to a ground electrode
s 4. 3 4HE NEUTRAL CONDUCTOR AND PROTECTIVE CONDUCTOR FOR THE OVERALL that is electrically separate from the ground terminal for the system.
system are completely separate. *2 A system that uses no grounding is referred to as an IT system.
s 4. # 4HE NEUTRAL CONDUCTOR AND PROTECTIVE CONDUCTOR FUNCTIONS FOR
the overall system are combined into a single conductor.

85
 Selection and application
3 3-16 Ground fault protection in system applications

Table 3-31 Comparison of grounding system (TN, TT and IT systems) characteristics and precautions for their use

Comparison Wiring system

item
TN-C TN-S TN-C-S
Circuit L1 L1 L1
diagram L2 L2 L2
L3 L3 L3
PEN N PE
PE N

Features s 4HE NEUTRAL CONDUCTOR AND PROTECTIVE s 4HE NEUTRAL CONDUCTOR AND PROTECTIVE s 4HE NEUTRAL CONDUCTOR AND PROTECTIVE
conductor functions for the overall conductor for the overall wiring system conductor functions for part of the wiring
system are combined into a single are completely separate. system are combined into a single
conductor. s 4HE PROTECTIVE CONDUCTOR 0% IS EITHER A conductor.
s !LL EXPOSED CONDUCTIVE PARTS OF THE metal sheath on the supply cable for the s 4HE MOST COMMON CONlGURATIONS ARE
equipment are connected to a PEN equipment or a conductor completely the TN-C wiring system on the power
conductor. separate from the system. supply side and a TN-S wiring system
s #ALCULATE THE FAULT LOOP IMPEDANCE FOR s !LL EXPOSED CONDUCTIVE PARTS OF THE on the equipment side.
shock protection and use an MCCB for equipment are connected to the s !LL EXPOSED CONDUCTIVE PARTS OF
system protection. conductor through the main ground the equipment are connected to a
s 7IDELY USED IN &RANCE THE 5+ AND THE terminal on the equipment. conductor through the main ground
United States terminal and the neutral line terminal
on the equipment, which are connected
together.
Indirect From the phase conductor to the ground for the exposed parts of the load equipment: Contact voltage of 50V max.
contact Zero impedance short-circuiting from the phase conductor in the equipment to the protective conductor or exposed parts:
protection U0 t la × Zs where U0 is the nominal voltage to ground (effective AC value), Ia is the maximum breaking time from the following
standards table as a function of U0 or the current that causes the protective device to trip automatically within the conditional time setting
of five seconds, and Zs is the fault loop impedance derived from the charging conductor from the power supply to the fault point
and the protective conductor between the fault point and the power supply.
s -AXIMUM BREAKING TIME FOR A 4. SYSTEM

U0 (V) 120 230 277 400 400 or higher

Maximum breaking time (s) 0.8 0.4 0.4 0.2 0.1

s #ONDITIONS FOR A MAXIMUM BREAKING TIME OF  S 4HE MAXIMUM BREAKING TIME IN THE TABLE ABOVE MAY BE EXCEEDED IN BRANCH
circuits that supply power to stationary equipment only, but 5 s or less is the allowable breaking time. Supplemental conditions
must be provided separately if other branch circuits that require the maximum breaking time given in the table are connected to
those branch circuits.
MCCB
s 7ITH INVERSE TIME DELAY CHARACTERISTICS )A IS THE CURRENT THAT CAN TRIP THE -##" AUTOMATICALLY WITHIN  S
s 7ITH INSTANTANEOUS TRIPPING CHARACTERISTICS )A IS THE SMALLEST CURRENT THAT CAN TRIP THE -##" AUTOMATICALLY
Applicable s -##" s -##" s -##"
protective s %,#" s %,#" APPLICABLE ONLY IN 4. 3 WIRING
device circuits only)
Application 1. Use only MCCBs. 1. Select a suitable ground fault 1. Select a suitable ground fault
(design) 2. Calculate the fault loop impedance. protection device for the protection protection device for the protection
precautions 3. Ignore the fault point impedance system. system.
between the phase conductor and the 2. Overcurrent breaking precautions: 2. ELCBs can only be installed in certain
protective conductor. Same as TN-C items 2 and 3. locations.
3. Overcurrent breaking precautions:
Same as TN-C items 2 and 3.

Note: The number of ground fault protection devices can be reduced once
potential equalization work and fault loop impedance calculations are
completed with TN systems, but never install low-voltage electrical
equipment using both TN and TT systems together in the same location.

86
 Selection and application
3-16 Ground fault protection in system applications
3

Continued

Comparison Wiring system

item
TT IT
Circuit L1 L1
diagram L2 L2
L3 L3
N

Features s !LL EXPOSED CONDUCTIVE PARTS OF THE EQUIPMENT ARE CONNECTED s !LL EXPOSED CONDUCTIVE PARTS OF THE EQUIPMENT ARE CONNECTED
to a ground electrode that is completely separate from the to a ground electrode that is completely separate from the
power supply ground. power supply ground.
s 4HIS SYSTEM IS THE MOST COMMONLY USED IN *APAN s 4HE POWER SUPPLY IS CONNECTED TO GROUND THROUGH INSERTED
ground impedance or is completely disconnected from
ground.
s 4HIS WIRING SYSTEM IS WIDELY USED IN .ORWAY )N *APAN
however, greater emphasis is placed on circuits that supply
power without interruption rather than on those that shut down
the power supply.
Indirect 50V t Ia × RA 50V t Id × RA
contact RA: Sum of the ground resistance and the protective conductor RA: Same as that on the left.
protection resistance connected to exposed conductive parts. Id: Ground fault current at the first occurrence of a ground
standards Ia: Current that trips the MCCB automatically. (With an ELCB, fault where impedance between the phase conductor and
Ia is the rated sensitivity current I'n.) exposed conductor parts can be ignored. It is derived
The MCCB is as follows. from the leak current and total ground impedance of the
s 7ITH INVERSE TIME DELAY CHARACTERISTICS )A IS THE CURRENT THAT electrical equipment.
can trip the MCCB automatically within 5 s. s )NSTALL AN INSULATION MONITORING DEVICE THAT INDICATES THE
s 7ITH INSTANTANEOUS TRIPPING CHARACTERISTICS )A IS THE SMALLEST first occurrence of a ground fault in order to maintain an
current that can trip the MCCB automatically. uninterrupted power supply.
s 0OWER SUPPLY SHUTDOWN CONDITIONS FOLLOWING THE lRST
occurrence of a ground fault or with the second occurrence of
a ground fault should be provided separately.
Applicable s -##" ONLY IF 2A is very low however) s )NSULATION MONITORING DEVICE
protective s %,#" s -##"
device s %,#"
Application 1. Select a suitable ground fault protection device for the 11.Select a suitable ground fault protection device for the
(design) protection system. protection system.
precautions 2. Overcurrent breaking precautions: 2. The power supply can shut down automatically when a
s 4HE ADDITIONAL CONDITIONS OUTLINED ABOVE MUST BE PROVIDED second ground fault occurs with overcurrent breaking.
separately. 3. Id t I'n when leak current breaking is used. Here, the power
s /THER PRECAUTIONS ARE THE SAME AS 4. # ITEMS  AND  supply can shut down automatically when the first ground
fault occurs.

87
88
 Environment and usage
Chapter 4 precautions
CONTENTS

4-1 Standard conditions ............................................................................................90

4-2 Application to special environments
4-2-1 High-temperature, high-humidity applications ..............................................................91
4-2-2 Cold climate applications..............................................................................................91
4-2-3 High altitude applications .............................................................................................91
4-2-4 Application to special atmospheres ..............................................................................92

4-3 Connection precautions

4-3-1 Reversed connection ....................................................................................................93
4-3-2 Tightening torque .........................................................................................................93

4-4 Malfunction due to transient inrush current.............................................94

89
 Environment and usage precautions
4 4-1 Standard conditions

4-1 Standard conditions

Because ambient conditions have a significant effect on the
short-circuit and overload characteristics, durability, and
insulating properties of circuit breakers, the conditions under
which they are used must be clarified.
For reference, Table 4-1 lists the standard operating conditions
for FUJI MCCB performance. If the ambient conditions under
which a circuit breaker is to be used differ significantly from
these standards, the circuit breaker’s characteristics may differ
considerably, and appropriate modification of usage criteria is
necessary.

Table 4-1 Standard conditions for MCCBs (IEC 60947-1)

Ambient Operating –5 to 40°C (the average temperature

temperature through 24-hour does not exceed 35°C)
Storage or –25 to 55°C or the temperature under
transport 24-hour does not exceed 70°C
Relative humidity 85% max.
Altitude 2000m max.
Pollution degree 3

90
 Environment and usage precautions
4-2 Application to special environments
4

4-2 Application to special environments 4-2-3 High altitude applications

4-2-1 High-temperature, high-humidity Special care must be taken when using MCCBs at altitudes
higher than 2000m because the lower air pressure (about
applications 0.8atm at 2000m and about 0.5atm at 5500m) at higher
(1) High temperature condition altitudes reduces the cooling effect and dielectric strength of
the air. When using MCCBs under these conditions, multiply
The temperature of each component of an MCCB is the the rated voltage and rated current by a correction factor from
sum of the ambient temperature and the temperature rise in Table 4-3 as recommended by ANSI C37.13-1981. Observe
the component due to current flow in the MCCB. When the the preceding precautions for cold climate applications as well
ambient temperature is higher than 40°C, the continuous because temperatures generally drop at higher altitudes.
carrying current should be derated to keep the temperature of
MCCB internal insulators and other materials within standard.
Thermal-magnetic type circuit breakers without a temperature Table 4-3 Rated voltage and rated current correction factors for
compensation device tend to trip with currents below their high altitude
rated current. It is recommended that the continuous carrying Altitude (m) Rated voltage Rated current
current be reduced to the current shown in Table 4-2.
2000m max. 1.00 1.00
Table 4-2 Current decrease due to ambient temperature 2600m max. 0.95 0.99

Ambient temperature (°C) Decrease 3900m max. 0.80 0.96

50 90% max.
60 80% max.

(2) High humidity condition

MCCBs to be used in excessively humid locations should be
housed in a moisture-proof cabinet, or thorough maintenance
and inspection should be conducted to prevent loss of
insulation properties or rusting of metallic mechanical parts.
When an MCCB is housed in a moisture-proof enclosure, the
temperature inside the enclosure is liable to change suddenly
when the related equipment is powered up or shut down,
and condensation may form. This problem can be averted by
installing a heater inside the enclosure.
4-2-2 Cold climate applications
At –5°C or lower temperatures, MCCB metallic parts and
insulators may become brittle and the viscosity of the lubricant
used in its mechanical parts changes; therefore, provisions
should be made to avoid low ambient temperatures, such as
installing near a heater. Since the operating characteristics of
a thermal-magnetic type MCCB are temperature dependent,
the MCCB’s relationship to the equipment it is to protect must
be considered when choosing the appropriate current rating.
Although the switching, trip, and short-circuit interruption
characteristics are not adversely affected at –20°C, installation
of a heater nearby is recommended to reduce adverse effects
of low temperatures. When shipped, temperatures as low
as –40°C present no problem, but the breakers should be
shipped in the off or tripped state to minimize brittleness.

91
 Environment and usage precautions
4 4-2 Application to special environments

4-2-4 Application to special atmospheres

(1) Corrosive gas and salt (2) Others
The contacts of MCCBs are generally made of silver or silver Table 4-5 shows special atmosphere problems and protective
alloy that readily forms a sulfide film on contact with sulfurized measures.
gas. Although this may degrade the quality of the contacts, the
film peels off easily so the problem is not significant, especially
with frequent switching. Intentional switching may be required
periodically when ordinary switching occurs infrequently. An
MCCB designed for special atmospheres should be used in
areas with high concentrations of sulfurized gas.

Table 4-4 Corrosive gas effects and protective measures

Gas type Effect on metal Effect on MCCB application

insulation
materials
Hydrogen (1) Copper and copper alloy: No problems Note:
sulfide gas A sulfide film develops that forms a Gas density (ppm) *1
Use parts treated
(H2S) high-resistance layer. Components for anti-corrosion.
that make actual physical contact 0 to 0.02 to 0.07 to 0.3 to *2
Protective
as well as components that operate Parts Parts measures for
with high levels of mechanical Standard parts equipment and
treated for treated for
stress, such as terminals, require anti- anti- control panels
anti-corrosion measures like surface *1 corrosion corrosion (A) Lower the
treatment using Sn plating or clear and (B) or and (D) humidity with
coating with lacquer. (C) equipment like
(2) Silver and silver alloy: *2 a space heater
Although a sulfide film develops, it is to prevent
not a problem here because the film condensation.
peels off the contact with arcing or (B) Use an
sliding action during switching. activated
(3) No problems have been found with charcoal filter
other metals. to improve the
environment.
Sulfurous acid High temperature and high humidity No problems
0 to 0.04 to 0.5 to (C) Install the
gas (SO2) conditions that are particularly prone to
100 packing
Nitrous acid condensation will accelerate corrosion. Parts treated for provided for
gas (NO2) There is less chance of corrosion with anti-corrosion the doors and
humidity at 65% or lower. %RH and (A+C) or (B)
*1 seal the control
*2 panel floor as
well as cable
65 ports.
Standard parts (D) Use an air
purging system.

Chlorine gas Chlorine gas is far more corrosive than Moisture

(CI2) nitrous acid gas or sulfurous acid gas. absorbed 0 to 0.02 to 0.1 to
Because it corrodes just about any by premixed Standard parts Parts treated
metal, protective measures are critical polyester for anti-
for equipment and control panels. lowers its corrosion and
insulation *1 (D)
resistance.
*2

Table 4-5 Special environment problems and protective measures

Environment Potential problems Protective measures

Water vapor, water drops and s -ETAL CORROSION s 0LACE IN A WATERPROOF CASING )0 
oil vapor s -OISTURE ABSORBED BY INSULATION MATERIAL s #ONDUCT PERIODIC MAINTENANCE INSPECTIONS
s ,OWER INSULATION RESISTANCE
Dust s #ONTACT FAILURE s 0LACE IN A DUSTPROOF CASING )08 
s 0OOR INSULATION
Flammable gas s %XPLOSIVE COMBUSTION s $O NOT USE IN THIS ENVIRONMENT

92
 Environment and usage precautions
4-3 Connection precautions
4

4-3 Connection precautions

4-3-1 Reversed connection 4-3-2 Tightening torque
The power supply side and the load side are indicated on the Conductor connections should be tightened to the specified
following products. The breaking capacity for power supply torque because loose connections may cause overheating or
reverse connection is different than that for regular connection. malfunctioning while overtightening may damage the screw or
Regular connection Reverse connection the molded plastic. Always use the appropriate screwdriver for
the screw head.
ON ON
Soldering must not be done when using a box-type terminal
connection.

OFF OFF

Table 4-8 Breaking capacity for MCCB connected in reverse

Model number Reverse connection breaking capacity

[kA] (JIS C 8201-2-1 Ann. 2)
200V 400V
BW32AAG 2.5 –
BW32SAG 5 2.5
BW50AAG 2.5 –
BW50EAG 5 2.5
BW50SAG 10 2.5
BW50RAG 15 2.5
BW63EAG 5 2.5
BW63SAG 10 2.5
BW63RAG 15 2.5
BW100AAG 5 –
BW100EAG 15 2.5

Note: Reverse connection is possible with standard products of 125AF or higher.

93
 Environment and usage precautions
4 4-4 Malfunction due to transient inrush current

4-4 Malfunction due to transient inrush current

An MCCB may trip if the overcurrent detection device detects
higher than normal transient current, like motor starting
current or transformer exciting inrush current. One way to
prevent this is to select an MCCB with instantaneous tripping
characteristics higher than the motor starting current or
transformer exciting inrush current.

94
 Maintenance inspections
Chapter 5
CONTENTS

5-1 Faults and causes ................................................................................................96

5-2 Periodic inspections
5-2-1 Initial inspection ............................................................................................................98
5-2-2 Periodic inspections .....................................................................................................98
5-2-3 Inspection following overcurrent tripping ......................................................................99

5-3 Replacement recommendations

5-3-1 Recommendations for MCCB deterioration diagnosis and replacement ....................100
5-3-2 Recommended replacement guidelines based on switching durability ......................100

95
 Maintenance inspections
5 5-1 Faults and causes

5-1 Faults and causes

Table 5-1 shows the appropriate countermeasure to take for faults that occur during MCCB operation.

Table 5-1 Troubleshooting

Type of fault Fault status or location Possible cause Countermeasure

Abnormal Abnormally high terminal s ,OOSE TERMINAL OR CONDUCTOR SCREW Tighten the screw. *
heat temperature
Burned insulation material in the s (EAT GENERATED BY EXCESSIVE CONTACT RESISTANCE Repair or replace with a new part. *
terminal section s ,OOSE TERMINAL OR CONDUCTOR SCREW
Abnormally high molded case s (EAT GENERATED BY EXCESSIVE CONTACT RESISTANCE Replace with a new part. *
temperature (exceeding 70°C)
s 3IGNIlCANT HIGHER HARMONIC CURRENT IN THE LOAD CURRENT Insert reactors to reduce the distortion
factor or re-evaluate the rated current
selection.
s (EAT GENERATED IN THE SOLENOID COIL HYDRAULIC MAGNETIC Re-evaluate the rated current selection
type) by high-frequency current (400Hz, etc.) or use a thermal-magnetic type. *
s ,OOSE INTERNAL SCREW Replace with a new part. *
s (IGH CURRENT DENSITY CAUSED BY A BROKEN BRAIDED WIRE WIRE Use parts treated for anti-corrosion.
broken due to corrosive gas in the operating environment)
Faulty Making fault s 4HE -##" HAS NOT RESET AFTER TRIPPING Reset the MCCB.
operation
s 6OLTAGE HAS BEEN APPLIED TO A SHUNT TRIP DEVICE Inspect the wiring. *
Reset fault s 4HE UNDERVOLTAGE TRIP DEVICE HAS NOT BEEN ENERGIZED Turn on the power supply.
s 4HE -##" HAS NOT COOLED SUFlCIENTLY FOLLOWING AN Let the MCCB cool and then reset it.
overcurrent trip.
s 4HE BIMETAL ELEMENT HAS CORRODED OR IS OTHERWISE DEFORMED Replace with a new part. *
s 4HE NUMBER OF TRIP OPERATIONS HAS EXCEEDED THE DURABILITY OF
the MCCB. (The shunt trip device or undervoltage trip device
tripped too many times.)
s &AULTY MECHANISM
Breaker The breaker trips in a closed s 4HE AMBIENT TEMPERATURE IS ABNORMALLY HIGH —# OR Use ventilation or some other means to
tripping circuit with less than the rated higher). lower the ambient temperature.
current.
s (EAT GENERATED BY A LOOSE TERMINAL SCREW WITH THERMAL Tighten any loose screws. *
magnetic type)
s (EAT GENERATED INSIDE THE -##" Replace with a new part. *
s 3HOCK AND VIBRATION Take action like cushioning to reduce
shock and vibration.
s 4HE LOAD CURRENT HAS EXCEEDED THE RATED CURRENT Re-evaluate the rated current selection.
(Example: The motor is running in overload, undervoltage or
overvoltage conditions).
Starting current trips the MCCB s %ITHER MOTOR STARTING CURRENT OR TRANSFORMER EXCITING INRUSH Change the instantaneous trip current
current trips the MCCB. setting or the rated current. *
s 4RANSIENT INRUSH CURRENT DURING THE CHANGEOVER FROM STAR TO
delta connection trips the MCCB.
s )NCHING OPERATION INSTANTLY TRIPS THE -##"
s #APACITOR INRUSH CURRENT MERCURY LAMP OR PHASE ADVANCE
capacitor), incandescent lamp inrush current, or fluorescent
lamp starting current instantly trip the MCCB.
s )NTERMITTENT OPERATION SPOT WELDER OR MOLDING EQUIPMENT See 3-7-2, Chapter 3.
s (IGH STARTING CURRENT CAUSES AN INVERSE TIME DELAY TRIP Change the rated current. *
s ! LONG STARTING TIME CAUSES AN INVERSE TIME DELAY TRIP
s !BNORMAL LARGE CURRENT mOWS WHEN THE CIRCUIT CLOSES 3HORT Inspect the circuit and eliminate the
in a load side circuit) cause.
s ! LAYER INSULATION FAULT OCCURS IN THE MOTOR Repair or replace the motor. *
s ! MALFUNCTION OCCURS BECAUSE A CONTROL CIRCUIT IN A SHUNT TRIP Inspect wiring and repair the cables. *
or undervoltage trip device is connected improperly.
Buzzing Current flow is above the rated s 4HE SOLENOID COIL IN THE -##" OPERATES BECAUSE OF A Change the rated current. *
sound level. distorted current waveform (Inverter connected to the load).

Note: * Do not inspect or take any other action until you are sure there is no voltage applied to the MCCB terminals.

96
 Maintenance inspections
5-1 Faults and causes
5

Continued
Type of fault Fault status or location Possible cause Countermeasure
Faulty Faulty operation at higher than the s ,ACK OF COORDINATION WITH AN UPSTREAM CURRENT LIMITING FUSE Re-evaluate coordination or change the
operation due specified operating current or with an upstream circuit breaker. selection.
to overcurrent s !MBIENT TEMPERATURE IS EXTREMELY LOW Check the current correction.
s 4HE AMMETER GIVES AN INCORRECT READING BECAUSE OF HIGH
frequency current.
Accessory Motor operating mechanism fault s )MPROPER CONTROL CIRCUIT CABLE CONNECTION CAUSES FAULTY Inspect and repair the cables. *
fault operation.
s )MPROPER CONTROL CIRCUIT CABLE CONNECTION CAUSES OPERATION
to start and stop repeatedly. (Snake circuit formed by
connecting the control signal circuit in parallel.)
s ! DROP IN VOLTAGE DUE TO INSUFlCIENT CAPACITY ON THE POWER Use heavier gauge cable.
supply circuit cable causes faulty operation. Increase the power supply capacity
s )NSUFlCIENT CAPACITY OF THE CONTROL CIRCUIT POWER SUPPLY (transformer capacity, etc.).
s -AKE RUN AND RESET DO NOT WORK PROPERLY BECAUSE THE Re-adjust the stroke. *
moving distance of the control mechanism is not properly
adjusted.
Shunt trip device fault s ! DROP IN POWER SUPPLY VOLTAGE DUE TO INSUFlCIENT POWER Increase the power supply capacity. *
capacity for the control circuit causes faulty operation.
s ! DROP IN POWER SUPPLY CURRENT DUE TO INSUFlCIENT POWER
supply capacity causes faulty operation.
s #ONTINUOUS EXCITATION AN INCORRECT COIL RATING AND FAULTY COIL Replace the coil and replace the
anti-burnout contact operation or coil burnout due to welded contacts with coil anti-burnout
contacts. contacts. *
Undervoltage trip device fault s 4HE -##" DOES NOT TRIP DUE TO RESIDUAL MAGNETIC mUX AND Repair or replace with a new part. *
no voltage.
s 4HE -##" DOES NOT TRIP DUE TO AN IMPROPERLY MOVING STROKE
and no voltage.
Auxiliary switch and alarm switch s #URRENT EXCEEDING THE MICROSWITCH CONTACT RATING BURNS OUT Replace the accessories and insert
fault the contacts or welds them together. a control relay to reduce the load on
internal switch contacts.
s !N IMPROPER MICROSWITCH MOVING STROKE CAUSES FAULTY Replace or repair the microswitch. *
operation.

97
 Maintenance inspections
5 5-2 Periodic inspections

5-2 Periodic inspections

5-2-1 Initial inspection
When newly installed equipment first goes into operation, incorrect. This is why the items shown in Tables 5-2 and 5-3
there may be unexpected oversights or mistakes such that should be inspected before initial operation and again within
screws were not properly tightened or cable connections were the following month.

Table 5-2 Initial inspection and judgment criteria prior to the operation starting
Inspection item Criteria Countermeasures for defects
1. Inspect the area around the terminals to make sure no dust, frag- No foreign matter Vacuum up foreign matter. Wipe the
ments, pieces of wiring, screws, or other conductive foreign matter area with a dry cloth.
were left behind.
2. Inspect the MCCB case and cover to make sure there are no cracks No cracks or damage Replace the enclosure.
or damage.
3. Inspect the connector to make sure the conductors are securely Conductors are tightened to the Tighten conductors to the specified
tightened. specified torque torque.
4. Measure insulation resistance with a 500V DC megger. 5M: min. Replace with a new part.
Note: Do not inspect until you are sure there is no voltage applied to the MCCB terminals.

Table 5-3 Inspection and judgment criteria within one month after the operation starting
Inspection item Criteria Countermeasure for defects
1. Loose conductor connectors? Conductors tightened at the Tighten conductors at the specified
specified torque torque.
2. Inspect the area around the terminals to make sure no dust, frag- No noticeable dust, oil or Vacuum up the foreign matter. Wipe
ments, pieces of wiring, screws, or other conductive foreign matter conductive foreign matter the area with a dry cloth.
were left behind.
3. No abnormal temperature rise? No discoloration of the terminal Replace with a new part.
connectors or molded plastic due
to excessive heat
Note: Do not inspect until you are sure there is no voltage applied to the MCCB terminals.

5-2-2 Periodic inspections

No time-related durability performance criteria are determined unexpected failure. However, performance may decline for a
for MCCBs. Durability performance can vary significantly number of reasons, including dust accumulation, loose screws,
with the operating environment, operating load, switching wear on mechanical parts due to excessive switching, or
frequency, and the quality of periodic inspections and repairs. contact wear. This is why periodic inspections are important.
Proper operating conditions must be maintained at all Table 5-4 shows inspection standards and Table 5-5 shows
times in order to ensure MCCB performance and to prevent inspection procedures.
Table 5-4 Inspection standards
Conditions Environment Examples Inspection interval Remarks
Normal A location with a constant supply of A dustproof, air-conditioned Once every two or three Use standard specification
operating clean and dry air electrical equipment room years Once a year for MCCBs MCCBs.
conditions installed more than ten years Set inspection intervals
Once every six months for according to actual
MCCBs installed more than circumstances.
15 years
An indoor location with minimal dust Installed in a control panel in a Once a year
and no corrosive gases separate electrical equipment Once every six months for
room with no dustproofing or MCCBs installed more than
air conditioning, or inside an 10 years
enclosure. Once a month for MCCBs
installed more than 15 years
Poor A location with minimal dust con- Geothermal power generation Once every six months Once a Requires appropriate action.
environment taining nitrous acid gas, hydrogen equipment and sewage plants month for MCCBs installed for (See 4-2-4, Chapter 4.)
sulfide gas, salt or high-temperature as well as paper, steel, and more than 5 years
gases pulp plants
A location where people could not Chemical factories, quarries, Once a month Requires enclosing or other
stay for long periods, or a location or mines appropriate action.
with excessive dust or corrosive gas

98
 Maintenance inspections
5-2 Periodic inspections
5

Table 5-5 Inspection procedures

Inspection item Procedure Countermeasure
1. Presence or Inspect the surface of the MCCB and especially around the Vacuum up any dust, and wipe the area down with a dry, lint-
absence of terminals on the power supply side to make sure no dust or oil free cloth.
dust or other has accumulated.
contaminates Check to make sure that dust or other foreign matter has not
bridged the gap provided to increase creepage distance.
2. Exhaust gas Inspect the exhaust gas outlet for foreign matter like carbon or Replace the MCCB if soot or metal particles are found.
outlet metal particles adhering near the outlet that may be evidence See items 6 and 7 in this table to decide whether to replace
of overcurrent tripping. the MCCB when only a minute amount of soot or metal
particles is found.
3. Discolored Inspect the terminal for evidence of an abnormal temperature Some discoloration of silver plating is not a problem. Replace
terminal rise or advanced damage due to corrosive gases like the MCCB in case of advanced stages of discoloration or
hydrogen sulfide gas. damage to the insulation due to an abnormal temperature rise.
4. Loose terminal Check for loose terminal screws or cable tightening screws. Confirm the normal tightening torque for the screws and
screw Use standard tools for tightening. materials in advance, and never overtighten or undertighten
screws.
5. Switching Intentionally switch several times to prevent excessive wear Repair MCCBs that do not switch smoothly.
due to grease hardening, and use the sliding action of
contacts to stabilize contact resistance with a normally closed
MCCB.
6. Insulation Use a 500V DC megger to measure insulation resistance Replace the MCCB if the megger reading is below 5M:.
resistance between the main poles as well as between live parts and
ground. Remove all conductors prior to taking measurements.
7. Temperature Check the following items through load current. Replace the MCCB.
rise (1) The temperature of the molded case should not exceed
70°C.
(2) There should be no smoke or abnormal odors.

5-2-3 Inspection following overcurrent tripping

When an MCCB trips due to overcurrent, visually inspect it Table 5-7 Inspection item and recommended countermeasure
to see the extent of damage. Take action as prescribed in
Table 5-6 to prevent malfunction or failure if the MCCB is to be Inspection item Countermeasure
used again. 1. Measure insulation s )NSULATION RESISTANCE IS BELOW -:: Replace
Inspect the items in Table 5-7 and take the recommended resistance with a the MCCB.
action if the extent of MCCB damage due to overcurrent 500V DC megger s )NSULATION RESISTANCE IS HIGHER THAN -: but
tripping is not clear or is as listed in Table 5-6. less than 5M:: Conduct a dielectric strength
test (double the rated voltage for 1 minute).
Table 5-6 Extent of damage and recommended countermeasure The MCCB can be used temporarily as long
as test results indicate the voltage withstand
Extent of MCCB damage Countermeasure level is within specified limits, but replace the
MCCB as soon as possible.
1. The area around the exhaust gas outlet The MCCB can be used s )NSULATION RESISTANCE OF AT LEAST -:: The
is clean and no other foreign matter is again. MCCB can be reused.
visible.
2. Conduct periodic Take the recommended countermeasure
2. Black soot is visible in the area around See Table 5-7. inspections described in Table 5-5 if there is a problem.
the exhaust gas outlet.
3. The exhaust gas outlet is noticeably Replace the MCCB.
dirty and soot is clearly visible on the
handle.

99
 Maintenance inspections
5 5-3 Replacement recommendations

5-3 Replacement recommendations

An MCCB is generally thought to have exceeded its limit of economical by replacing the MCCB before it reaches one
durability when any of the following occurs. of the three preceding conditions. This is true as long as
s (IGH FAILURE RATES AND FREQUENT LOSSES DUE TO POWER SUPPLY the selected MCCB is the optimum choice (see Chapter 3)
interruptions and is used under standard operating conditions (see 4-1,
s $ECLINING PERFORMANCE THAT MAKES SAFE OPERATION NO LONGER Chapter 4). The recommended period of replacement has no
sustainable bearing on the stated durability or warranty period.
s -ARKEDLY HIGHER MAINTENANCE COSTS DUE TO DETERIORATING Exactly when an MCCB should be replaced cannot be defined
performance in mere years because the replacement period will vary with
The recommended replacement period makes systems the stress brought on by the operating environment and
more efficient by ensuring power supply reliability and more operating conditions.

5-3-1 Recommendations for MCCB

deterioration diagnosis and replacement
Table 5-8 shows guidelines for the timing of MCCB
deterioration diagnosis and replacement.

Table 5-8 Guidelines for the timing of MCCB deterioration diagnosis and replacement
(Technical Rep. 142, Standard of Japan Electrical Manufactures)
Environment Example Guidelines for the timing Guidelines for the timing
of deterioration diagnosis of MCCB replacement
Normal A location with a constant supply of A dustproof, air-conditioned electrical 10 years 15 years
environment clean and dry air equipment room
An indoor location with minimal dust Installed in a control panel in a 7 years 13 years
and no corrosive gases separate electrical equipment
room with no dustproofing or air
conditioning, or inside an enclosure.
Poor A location with high humidity and Geothermal power generation 3 years About 3 to 7 years
environment minimal dust containing salt or equipment and sewage plants as well
gases like nitrous acid gas and as paper, steel, and pulp plants
hydrogen sulfide gas
A location where people could not Chemical factories, quarries, or mines 1 year About 1 to 3 years
stay for long periods, or a location
with excessive dust or corrosive gas

5-3-2 Recommended replacement guidelines

based on switching durability
The number of switching operations determines the durability
of an MCCB in frequent switching applications. MCCBs should
be replaced before they exceed the value in any column in
Table 5-9.

Table 5-9 Switching durability performance (IEC 60947-2)

Frame size Number of switching operations Number of trips by a shunt trip device or undervoltage
trip device
With current Without current Total
100A max. 1500 8500 10000 10% of the total number of switching operations
300A 1000 7000 8000
600A 1000 4000 5000
800A 500 2500 3000
1000A 500 2500 3000
Over 1000A 500 2500 3000

100
 Short-circuit current
Chapter 6 calculation
CONTENTS

6-1 Calculating short-circuit current

6-1-1 Calculation objective ..................................................................................................102
6-1-2 Calculation formula.....................................................................................................102
6-1-3 Calculating short-circuit current for three-phase circuits ............................................102
6-1-4 Impedance examples .................................................................................................104

101
 Short-circuit current calculation
6 6-1 Calculating short-circuit current

6-1 Calculating short-circuit current s 3TEP  #ONVERTING IMPEDANCE VALUES TO REFERENCE

values
6-1-1 Calculation objective (1) Reactance on the primary side of the
The damage from a short-circuit fault in a system circuit must transformer: %X1
be kept to a minimum with power receiving equipment. This
The reactance can usually be obtained from the power
is why the short-circuit current generated when a fault occurs
company. If the reactance is not known, then it can be found
must be accurately calculated for all points in the system.
by calculating back from the rated breaking capacity of the
Purpose of short-circuit current calculations circuit breaker installed on the primary side of the transformer.
1) To select the appropriate breaking capacity for overcurrent
%X1 = PB u 100 (%)
trip devices like MCCBs or fuses installed in the system.
2) To select the protective relay setting value that will ensure Q u 103
proper coordination at all points when a fault occurs. Q = Short-circuit capacity on the primary side (MVA)
3) To see how much short-circuit current the cables,
disconnectors, current transformers and other series-
connected devices can thermally and electrically withstand (2) Transformer impedance: %Zt
before the overcurrent trip device finally cuts off current. Transformer impedance is usually expressed as a percentage.
If the transformer capacity is used for the reference capacity,
then simply use %ZT. When the reference capacity and the
6-1-2 Calculation formula transformer capacity are different, however, then convert them
Short-circuit current is calculated from reference capacity and to a base reference capacity (%Zt) using the following formula.
reference voltage impedance. When the various quantities PT = PB
needed in the calculation are expressed in percentages, then (Converting percentages into another capacity)
%ZT %Zt
simply use Ohm’s Law.
When there is a single-phase transformer, treat it like a three-
6-1-3 Calculating short-circuit current for phase transformer, and set the impedance percentage at √3 /2
three- phase circuits times the obtained current value.

s 3TEP  3ETTING REFERENCE VALUES %Z (3ø) = 1 %Z (1ø)

2
First set calculation references, and then select appropriate
Calculate three-phase short-circuit current using the formula
values for the references. The rated capacity of the transformer
above, and multiply the obtained current by √3 /2.
is generally used for the reference capacity.
Reference capacity PB = PT (kVA) (3) Motor reactance: %Xm
PT = Transformer capacity Motor capacity is generally expressed in kW, so convert the
kW into kVA.
Reference voltage VB = VT (V)
Conversion to kVA | 1.5 u motor output (kW)
VT = Line voltage Use %Xm’ = 25% to convert the motor capacity into a base
Reference current reference capacity.

IB = IT = PT u 103 (A) PM = PB
—3VT %Xm' %Xm
Reference impedance (Formula for converting into another capacity)
ZB = VB2 VT2
= (:)
PB u 103 PT u 103 (4) Bus duct and cable impedance
These are normally expressed by cross sections (rated current
Fig. 6-1 Short-circuit capacity or
for the bus duct) and length.
ZC = (Ohms per unit length) u (Length) (:)
breaking capacity
Convert this value into a percentage.
Q (MVA) o j%X1
%ZC = ZC u 100%
PT (kVA) ZB
/VT (V) %ZT = %RT + j%XT
Bus duct jX3 (:) o j%X3 (If the value is given in ohms, convert it to a
percentage.)
Cable Cable
jX2 (:) o j%X2
R4 (:) + jX4 (:) R5n (:) + jX5n (:)
%R4 + j%X4 %R5n + j%X5n

F
j%Xm M Total capacity PM (kVA)
PM (kVA) = 1.5x (kW sum total)

102
 Short-circuit current calculation
6-1 Calculating short-circuit current
6

s 3TEP  #REATING AN IMPEDANCE MAP

Create an impedance map using the impedance calculated in
step 2. Sources of short-circuit current like a power supply and
motor constitute the same electric potential in an impedance
map. Connect these sources together with an infinite
busbar as shown in Fig. 6-2 and be very careful connecting
impedance in series or in parallel between the busbar and fault
point F when creating the impedance map.

s 3TEP  5NIFYING IMPEDANCE

Take the impedance map shown in Fig. 6-2 and use series-
parallel calculations to unify all impedance as shown in
Fig. 6-3.
%Z = %R + j%X

%Z = — (%R)2 + (%X)2

s 3TEP  #ALCULATING EFFECTIVE VALUES FOR SYMMETRICAL

short-circuit current
IF = (3ø) = IF (rms) sym (3ø)

= PB u 10 u 100
3
—3VB%Z
= IB u 100 [A]
%Z

Fig. 6-2
Infinite busbar
j%X1 j%X5 j%Xn
%RT %R5 %Rn
j%XT j%X5 j%Xn

j%X3

j%X2
%R4
j%X4
F

Fig. 6-3
Infinite busbar
%R
j%X
F

103
 Short-circuit current calculation
6 6-1 Calculating short-circuit current

6-1-4 Impedance examples

Table 6-1 Transformer impedance examples

Transformer 3-phase transformer
capacity (kVA) 6.3kV/210V 6.3kV/210V 20kV/420V 20kV/420V
Oil immersed self-cooling Cast-resin Oil immersed self-cooling Cast-resin
Impedance (%) Impedance (%) Impedance (%) Impedance (%)
ZT RT XT ZT RT XT ZT RT XT ZT RT XT
3
5
7.5
10
15
20 2.3 2.1 0.9 3.0
30 2.2 1.9 1.1 4.7 2.27 4.12
50 2.1 1.8 1.1 4.7 1.94 4.28
75 2.4 1.6 1.8 4.4 1.56 4.11
100 2.4 1.6 1.8 4.5 1.5 4.24
150 2.4 1.6 1.8 4.2 1.29 4.0
200 2.5 1.5 2.0 4.5 1.17 4.35
300 2.6 1.4 2.2 4.5 1.2 4.33
500 3.0 1.3 2.7 4.8 0.8 4.69 5.0 1.56 4.76 6.0 1.0 5.92
750 5.3 1.5 5.1 6.0 0.8 5.95 5.0 1.40 4.80 6.0 0.9 5.93
1000 5.1 1.4 4.9 7.0 0.4 6.96 5.0 1.26 4.84 6.0 0.8 5.95
1500 5.6 1.3 5.4 7.0 0.6 6.97 5.0 1.2 5.37 7.0 0.75 6.96
2000 6.3 1.3 6.2 7.5 0.65 7.47 5.0 1.1 5.39 7.0 0.7 6.96

Table 6-2 Impedance of rubber and plastic-sheathed cables

Impedance of 600V, 3-core (CV, EV, PV, VV) round stranded cable at 50Hz
Nominal conductor CV cable EV cable
cross section R (90°C) XL Z R (75°C) XL Z
(mm2) (:/km) (:/km) (:/km) (:/km) (:/km) (:/km)
2.0 12.5 0.0992 12.5 11.9 0.0992 11.9
3.5 6.78 0.0914 6.78 6.64 0.0914 6.64
5.5 4.51 0.0914 4.51 4.31 0.0914 4.31
8 3.14 0.0870 3.14 2.99 0.0870 2.99
14 1.76 0.0811 1.76 1.58 0.0811 1.58
22 1.10 0.0804 1.10 1.05 0.0804 1.05
38 0.653 0.0761 0.657 0.623 0.0761 0.628
60 0.408 0.0757 0.415 0.388 0.0757 0.395
100 0.242 0.0761 0.254 0.231 0.0751 0.243
150 0.159 0.0732 0.175 0.152 0.0732 0.169
200 0.126 0.0745 0.146 0.121 0.0745 0.142
250 0.100 0.0729 0.124 0.0962 0.0729 0.121
325 0.0808 0.0714 0.108 0.0775 0.0714 0.105

CV: Cross-linked polyethylene insulated power cable with vinyl sheath

EV: Polyethylene insulated power cable with vinyl sheath
PV: Ethylene propylene rubber insulated power cable with vinyl sheath
VV: Vinyl insulated power cable with vinyl sheath

104
 Short-circuit current calculation
6-1 Calculating short-circuit current
6

Table 6-3 Cable impedance examples (600V vinyl cable)

Cable gauge Reactance per meter of cable (:) Resistance per meter of cable (:)
Insulated wire or cable inside Copper tube cable or vinyl Indoor cable with insulator
a steel tube or duct tube cable with no duct
ø1.6mm 0.00020 0.00012 0.00031 0.0089
ø2mm 0.0056
ø3.2mm 0.0022
5.5mm2 0.0033
8mm2 0.0023
14mm2 0.00015 0.00010 0.00026 0.0013
22mm2 0.00082
30mm2 0.00062
38mm2 0.00048
2
50mm 0.00013 0.00009 0.00022 0.00037
60mm2 0.00030
80mm2 0.00023
100mm2 0.00018
125mm2 0.00014
150mm2 0.00012
200mm2 0.00009
2
250mm 0.00007
325mm2 0.00005

.OTES s !DD  REACTANCE ON THE POWER SUPPLY SIDE TO lND THE VALUE BECAUSE
reactance is 1.2 times higher at 60Hz.
s 5SE  OR  THE ACTUAL CABLE LENGTH TO CALCULATE REACTANCE AND
resistance when using two or three cables connected in parallel.

Table 6-4 Bus bar and bus duct impedance examples (50Hz) Data: Furukawa Electric Co., Ltd.
Material Rated current Regular bus duct
(A) Conductor dimensions Resistance Reactance X Impedance Z
(mm) (:/m) (:/m) (:/m)
Aluminum 200 6 u 25 1.93 u 10-4 1.25 u 10-4 2.3 u 10-4
(Al) 400 6 u 50 0.97 u 10 -4
0.909 u 10 -4
1.33 u 10-4
600 6 u 75 0.657 u 10-4 0.72 u 10-4 0.974 u 10-4
800 6 u 125 0.404 u 10-4 0.516 u 10-4 0.655 u 10-4
1000 6 u 150 0.343 u 10 -4
0.45 u 10-4
0.566 u 10-4
1200 6 u 100 u 2 0.249 u 10 -4
0.882 u 10 -4
0.916 u 10-4
1500 6 u 125 u 2 0.201 u 10 -4
0.790 u 10 -4
0.815 u 10-4
2000 6 u 200 u 2 0.133 u 10-4 0.588 u 10-4 0.603 u 10-4
Copper 200 3 u 25 2.41 u 10-4 1.312 u 10-4 2.74 u 10-4
(Cu) 400 6 u 40 0.751 u 10 -4
1.02 u 10-4
1.267 u 10-4
600 6 u 50 0.607 u 10 -4
0.91 u 10-4
1.094 u 10-4
800 6 u 75 0.412 u 10 -4
0.72 u 10-4
0.830 u 10-4
1000 6 u 100 0.315 u 10 -4
0.60 u 10-4
0.678 u 10-4
1200 6 u 125 0.261 u 10-4 0.511 u 10-4 0.573 u 10-4
1500 6 u 150 0.221 u 10-4 0.449 u 10-4 0.500 u 10-4
2000 6 u 125 u 2 0.129 u 10 -4
0.79 u 10-4
0.800 u 10-4

105
Glossary

Glossary
Alarm switch An auxiliary switch which operates only upon the tripping of the circuit
breaker with which it is associated.

Ambient air temperature Temperature, determined under prescribed conditions, of the air surrounding
the complete switching device or fuse.

Anti-pumping device A device which prevents reclosing after a close-open operation as long as the
device initiating closing is maintained in the position for closing.

Applied voltage (for a switching Voltage which exists across the terminals of a pole as a switching device just
device) before the making of the current.
NOTE: This definition applies to a single-pole device. For a multipole device it
is the phase-to-phase voltage across the supply terminals of the device.

Arcing contact Arc contact on which the arc is intended to established.

Arcing time (of a multipole switching Interval of time between the instant of the first initiation of an arc and the
device) instant of final arc extinction in all poles.

Auxiliary contact Contact included in an auxiliary circuit and mechanically operated by the
switching device.

Auxiliary switch (of a mechanical Switch containing one or more control and/or auxiliary contacts mechanically
switching device) operated by a switching device.

Backup protection Overcurrent coordination of two overcurrent protective devices in series

where the protective device, generally but not necessarily on the supply side,
effects the overcurrent protection with or without the assistance of the other
protective device and prevents any excessive stress on the latter.

Breaking capacity (of a switching Value of prospective breaking current that a switching device or a fuse is
device or a fuse) capable of breaking at a stated voltage under prescribed conditions of use
and behavior.

Breaking current (of a switching device Current in a pole of a switching device or a fuse at the instant of initiation of
or a fuse) the arc during a breaking process.

Break time Interval of time between the beginning of the opening time of a mechanical
switching device (or the pre-arcing time of a fuse) and the end of the arcing
time.

Circuit breaker Mechanical switching device, capable of making, carrying and breaking
currents under normal circuit conditions and also making, carrying for
a specified time and breaking currents under specified abnormal circuit
conditions such as those of short- circuit.

Clearance Distance between two conductive parts, along a string stretched the shortest
way between these conductive parts.

Closing time Interval of time between the initiation of the closing operation and the instant
when the contacts touch in all poles.

Conditional short-circuit current Prospective current that a circuit or a switching device, protected by a
(of a circuit or a switching device) specified short- circuit protective device, can satisfactorily withstand for the
total operating time of that device under specified conditions of use and
behavior.

Conductive part Part which is capable of conducting current although it may not necessarily
be used for carrying service current.

Control circuit (of a switching device) All the conductive parts (other than the main circuit) of a switching device
which are included in a circuit used for the closing operation or opening
operation, or both, of the device.

106
 Glossary

Glossary
Conventional free-air thermal current The conventional free-air thermal current is the maximum value of test current
(Ith) to be used for temperature-rise tests of unenclosed equipment in free-air. The
value of the conventional free-air thermal current shall be at least equal to the
maximum value of the rated operational current of the unenclosed equipment
in eight-hour duty.

Conventional non-tripping current Specified value of current which the relay or release (trip device) can carry for
(of an overcurrent relay or release a specified time (conventional time) without operating.
(trip device))
Conventional tripping current Specified value of current which causes the relay or release (trip device) to
(of an overcurrent relay or release operate within a specified time (conventional time).
(trip device))
Creepage distance Shortest distance along the surface of an insulating material between two
conductive parts.
NOTE: A joint between two pieces of insulating material is considered part of
the surface.

Critical load current Value of breaking current, within the range of service conditions, at which the
arcing time is significantly extended.

Critical short-circuit current Value of breaking current, less than the rated short-circuit breaking capacity,
at which the arc energy is significantly higher than at the rated short-circuit
breaking capacity.

Current-limiting circuit breaker A circuit breaker with a break-time short enough to prevent the short-circuit
current reaching its otherwise attainable peak value.

Cut-off current (Let-through current) Maximum instantaneous value of current attained during the breaking
operation of a switching device or a fuse.
NOTE: This concept is of particular importance when the switching device or
the fuse operates in such a manner that the prospective peak current of the
circuit is not reached.

Disconnector Mechanical switching device which, in the open position, complies with the
requirements specified for the isolating function.

Exposed conductive part Conductive part which can readily be touched and which is not normally
alive, but which may become alive under fault conditions.
NOTE: Typical exposed conductive parts are walls of enclosures, operating
handles, etc.

Frame size A term designating a group of circuit breakers, the external physical
dimensions of which are common to a range of current ratings. Frame size
is expressed in amperes corresponding to the highest current rating of the
group. Within a frame size, the width may vary according to the number of
poles.

Fuse Device that, by the fusing of one or more of its specifically designed and
proportioned components, opens the circuit in which it is inserted by breaking
the current when this exceeds a given value for a sufficient time. The fuse
comprises all the parts that form the complete device.

Fuse-element Part of the fuse-link designed to melt under the action of current exceeding
some definite value for a definite period of time.

Fuse-link Part of a fuse (including the fuse-element(s)) intended to be replaced after

the fuse has operated.

Impulse withstand voltage (Uimp) Highest peak value of an impulse voltage, of prescribed form and polarity,
which does not cause breakdown under specified conditions of test.

Instantaneous relay or release Relay or release (trip device) which operates without any intentional time-
(trip device) delay.

107
Glossary

Glossary
Inverse time-delay overcurrent relay or An overcurrent relay or release (trip device) which operates after a time-delay
release (trip device) inversely dependent upon the value of the overcurrent.
NOTE: Such a relay or release (trip device) may be designed so that the time-
delay approaches a definite minimum value for high values of overcurrent.

Isolating distance (of a pole of a Clearance between open contacts meeting the safety requirements specified
mechanical switching device) for disconnectors.

I2t characteristic of a circuit breaker Information (usually a curve) giving the maximum values of I2t related to
break time as a function of prospective current (r.m.s. symmetrical for AC) up
to the maximum prospective current corresponding to the rated short-current
breaking capacity and associated voltage.

Joule integral (I2t) Integral of the square of the current over a given time interval:
I 2t = ³ i 2dt
Let-through current ( = Cut-off current) See "Cut-off current."

Live part Conductor or conductive part intended to be energized in normal use,

including a neutral conductor but, by convention, not a PEN conductor.
NOTE: This term does not necessarily imply a risk of electric shock.

Magnetic overload relay or release Overload relay or release (trip device) depending for its operation on the force
(trip device) exerted by the current in the main circuit exciting the coil of an electromagnet.
NOTE: Such a relay or release (trip device) usually has an inverse time-delay/
current characteristic.

Main circuit (of a switching device) All the conductive parts of a switching device included in the circuit which it is
designed to close or open.

Main contact Contact included in the main circuit of a mechanical switching device,
intended to carry, in the closed position, the current of the main circuit.

Make time Interval of time between the initiation of the closing operation and the instant
when the current begins to flow in the main circuit.

Maximum prospective peak current Prospective peak current when initiation of the current takes place at the
(of an AC circuit) instant which leads to the highest possible value.
NOTE: For a multipole device in a polyphase circuit, the maximum
prospective peak current refers to one pole only.

Molded case circuit breaker A circuit breaker having a supporting housing of molded insulating material
forming an integral part of the circuit breaker.

Neutral conductor (symbol N) Conductor connected to the neutral point of a system and capable of
contributing to the transmission of electrical energy.
NOTE: In some cases, the functions of the neutral conductor and the
protective conductor may be combined under specified conditions in one and
the same conductor referred to as the PEN conductor [Symbol PEN].

Opening time (of a mechanical Interval of time between the specified instant of initiation of the opening
switching device) operation and the instant when the arcing contacts have separated in all
poles.
NOTE: The instant of initiation of the opening operation, i.e. the application of
the opening command (e.g. energizing the release), is given in the relevant
product standard.

Overcurrent Current exceeding the rated current.

108
 Glossary

Glossary
Overcurrent protective coordination Coordination of two or more overcurrent protective devices in series to ensure
overcurrent discrimination (selectivity) and/or backup protection.

Overcurrent relay or release Relay or release (trip device) which causes a mechanical switching device to
(trip device) open with or without time-delay when the current in the relay or release (trip
device) exceeds a predetermined value.
NOTE: This value can in some cases depend upon the rate-of-rise of current.

Overload Operating conditions in an electrically undamaged circuit which cause an

overcurrent.

Overload current Overcurrent occurring in an electrically undamaged circuit.

Overload relay or release (trip device) Overcurrent relay or release (trip device) intended for protection against
overloads.

Pollution Any condition of foreign matter, solid, liquid or gaseous (ionized gases), that
may affect dielectric strength or surface resistivity.

Pollution degree (of environmental Conventional number based on the amount of conductive or hygroscopic
conditions) dust, ionized gas or salt and on the relative humidity and its frequency of
occurrence, resulting in hygroscopic absorption or condensation of moisture
leading to reduction in dielectric strength and/or surface resistivity.

Prospective breaking current (for a Prospective current evaluated at a time corresponding to the instant of the
pole of a switching device or a fuse) initiation of the breaking process.

Prospective making current (for a pole Prospective current when initiated under specified conditions.
of a switching device) NOTE: The specified conditions may relate to the method of initiation, e.g.
by an ideal switching device, or to the instant of initiation, e.g., leading to the
maximum prospective peak current.

Prospective peak current Peak value of a prospective current during the transient period following
initiation.

Prospective symmetrical current Prospective current when it is initiated at such an instant that no transient
(of an AC circuit) phenomenon follows the initiation.

Rated current (In) For circuit breakers, the rated current is the rated uninterrupted current (Iu)
and is equal to the conventional free-air thermal current (Ith).

Rated insulation voltage (Ui) The insulation voltage of an equipment is the value of voltage to which
dielectric tests and creepage distances are referred.

Rated operational voltage (Ue) A rated operational voltage of an equipment is a value of voltage which,
combined with a rated operational current, determines the application of the
equipment and to which the relevant tests and the utilization categories are
referred.

Rated uninterrupted current (Iu) The rated uninterrupted current of an equipment is a value of current, stated
by the manufacturer, which the equipment can carry in uninterrupted duty.

Selectivity limit current (Is) The selectivity limit current is the current coordinate of the intersection
between the total time-current characteristic of the protective device on the
load side and the pre- arcing (for fuses), or tripping (for circuit breakers) time-
current characteristic of the other protective device.

Service short-circuit breaking capacity A breaking capacity for which the prescribed conditions according to a
(Ics) specified test sequence include the capability of the circuit breaker to carry
its rated current continuously.

109
Glossary

Glossary
Short-circuit breaking capacity Breaking capacity for which prescribed conditions include a short-circuit at
(Icn) the terminals of the switching device.

Short-circuit current Overcurrent resulting from a short-circuit due to a fault or an incorrect

connection in an electric circuit.

Short-circuit making capacity Making capacity for which prescribed conditions include a short-circuit at the
(Icm) terminals of the switching device.

Short-circuit protective device Device intended to protect a circuit or parts of a circuit against short-circuit
(SCPD) currents by interrupting them.

Short-time delay Any intentional delay in operation within the limits of the rated short-time
withstand current.

Short-time withstand current Current that a circuit or a switching device in the closed position can carry
(Icw) during a specified short time under prescribed conditions of use and behavior.

Shunt release (trip device) A release (trip device) energized by a source of voltage.
NOTE: The source of voltage may be independent of the voltage of the main
circuit.

Take-over current (IB) Current coordinate of the intersection between the time-current characteristics
of two overcurrent protective devices.

Thermal overload relay or release Inverse time-delay overload relay or release (trip device) depending for
(trip device) its operation (including its time-delay) on the thermal action of the current
flowing in the relay or release (trip device).

Time-current characteristic Curve giving the time, e.g. pre-arcing time or operating time, as a function of
the prospective current, under stated conditions of operation.

Tripping (operation) Opening operation of a mechanical switching device initiated by a relay or

release (trip device).

Ultimate short-circuit breaking A breaking capacity for which the prescribed conditions according to a
capacity (Icu) specified test sequence do not include the capability of the circuit breaker to
carry its rated current continuously.

Undervoltage relay or release Relay or release (trip device) which permits a mechanical switching device
(trip device) to open or close, with or without time-delay, when the voltage across the
terminals of the relay or release (trip device) falls below a predetermined
value.

Working voltage Highest r.m.s. value of the AC or DC voltage across any particular insulation
which can occur when the equipment is supplied at rated voltage.

110
 Safety Considerations
Operate (keep) in the environment specified in the operating instructions and manual. High temperature, high humidity, condensation, dust,
corrosive gases, oil, organic solvents, excessive vibration or shock might cause electric shock, fire, erratic operation or failure.
For safe operation, before using the product read the instruction manual or user manual that comes with the product carefully or consult the
Fuji sales representative from which you purchased the product.
Products introduced in this catalog have not been designed or manufactured for such applications in a system or equipment that will affect
human bodies or lives.
Customers, who want to use the products introduced in this catalog for special systems or devices such as for atomic-energy control,
aerospace use, medical use, passenger vehicle, and traffic control, are requested to consult with Fuji Electric FA.
Customers are requested to prepare safety measures when they apply the products introduced in this catalog to such systems or facilities
that will affect human lives or cause severe damage to property if the products become faulty.
For safe operation, wiring should be conducted only by qualified engineers who have sufficient technical knowledge about electrical work or
wiring.
Follow the regulations of industrial wastes when the product is to be discarded.
For further questions, please contact your Fuji sales representative or Fuji Electric FA.

5-7, Nihonbashi Odemma-cho, Chuo-ku, Tokyo, 103-0011, Japan

URL http://www.fujielectric.co.jp/fcs/eng

Information in this catalog is subject to change without notice. Printed in Japan 2017-9 PDF FOLS 62D4-E-0058